Ford - Expedition 4wd - Workshop Manual - 1997 - 1997

Factory Workshop Manual Make Ford Model Expedition 4wd Engine and year V8-4.6L SOHC VIN 6 (1997) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 ( P 0500 ) P0500 - P0504: Testing and Inspection P0500 ( P 0500 ) For diagnosis of P0500 refer to the system experiencing the problem. Computers and Control Systems or Transmission Control System Refer to pinpoint test DP1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DP - Vehicle Speed Sensor (VSS) For complete Engine Control diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Transfer Case Pinpoint Test C, See: Transmission and Drivetrain/Transfer Case/Testing and Inspection/Pinpoint Tests/C: Vehicle Doesn't Shift Between 4H and 4L Ranges For complete Transfer Case diagnostic information, See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Windshield Wiper Pinpoint Test F, See: Wiper and Washer Systems/Testing and Inspection/Pinpoint Tests/F: The Speed Dependent Interval Mode Doesn't Operate Properly For complete Windshield Wiper diagnostic information, See: Wiper and Washer Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1480 - P1484, ( P1481 P1482 P1483 1480 1481 1482 1483 1484 ) > System Information > System Diagnosis > P1483 P1480 - P1484: Testing and Inspection P1483 For diagnosis of P1483 refer to the system experiencing the problem. Computers and Control Systems or Transmission Control System Refer to pinpoint test XB10. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/XB - Variable Load Control Module (VLCM)/XB4 XB10 For complete Engine Control diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Transfer Case Pinpoint Test C, See: Transmission and Drivetrain/Transfer Case/Testing and Inspection/Pinpoint Tests/C: Vehicle Doesn't Shift Between 4H and 4L Ranges For complete Transfer Case diagnostic information, See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1805 - P1809, ( P1806 P1807 P1808 1805 1806 1807 1808 1809 ) > System Information > System Diagnosis > P1808 P1805 - P1809: Testing and Inspection P1808 For diagnosis of P1808 refer to the system experiencing the problem. Suspension Control For complete Suspension Control diagnostic information, See: Steering and Suspension/Suspension/Suspension Control ( Automatic - Electronic )/Testing and Inspection Transfer Case Refer to Pinpoint Test E, See: Transmission and Drivetrain/Transfer Case/Testing and Inspection/Pinpoint Tests/E: Low Range, or A4WD Indicator Not Operating Properly For complete Transfer Case diagnostic information, See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1865 - P1869, ( P1866 P1867 P1868 1865 1866 1867 1868 1869 ) > System Information > System Diagnosis > P1867 P1865 - P1869: Testing and Inspection P1867 P1867 is an information code (there is no testing for this code). Code Description: Internal to Transfer Case NOTE: If the DTC is stored, the transfer case cannot be shifted until the DTC is cleared and the ignition switch is cycled. Repair any other DTC's retrieved first and re-test. Transfer Case CONTACT PLATE - General Circuit Failure (One or More Plates Open or Short to Ground). Refer to wiring diagrams to diagnose this circuit, See: Transmission and Drivetrain/Transfer Case/Diagrams For complete Transfer Case diagnostic information, See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Accessory Delay Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 29 Junction Box Fuse/Relay Panel (Part 1 Of 2) The Accessory Delay Relay is located in the junction box fuse/relay panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Specifications Alarm Module: Specifications Passive Anti-Theft System Module Screws ............................................................................................................................... 4.5-6.3 Nm (41-56.2 In Lb) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Anti-Theft Transceiver Module Alarm Module: Locations Anti-Theft Transceiver Module Instrument Panel View The Anti Theft-Transceiver Module is located behind the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Anti-Theft Transceiver Module > Page 35 Alarm Module: Locations Passive Anti-Theft System Module Body View The Passive Anti-Theft System Module is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Anti-Theft Transceiver Module > Page 36 Alarm Module: Locations Remote Anti-Theft Personality Module Body Views Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Anti-Theft Transceiver Module > Page 37 The Remote Anti-Theft Personality Module is located behind left side of instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Controller Module Passive Anti-Theft System Control Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Controller Module > Page 40 Anti-Theft Transceiver Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Controller Module > Page 41 Alarm Module: Diagrams Remote Anti-Theft Personality Module Remote Anti-Theft Personality Module (C257) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Controller Module > Page 42 Remote Anti-Theft Personality Module (C256) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 43 Alarm Module: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the PATS module. 1. Disconnect the electrical connector. 2. Remove the two screws. 3. Remove the PATS module. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Specifications General Module: Specifications GEM Screws ........................................................................................................................................ .......................................... 0.9-1.3 Nm (8-12 In Lb) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Specifications > Page 47 General Module: Locations Instrument Panel View The Generic Electronic Module is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions General Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 50 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 51 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 52 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 53 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 54 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 55 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 56 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 57 General Module: Connector Views Generic Electronic Module (C239) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 58 Generic Electronic Module (C267) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 59 Generic Electronic Module (C240 ) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 60 Generic Electronic Module (C241) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 61 General Module: Electrical Diagrams Generic Electronic Module (Part 1 Of 5) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 62 Generic Electronic Module (Part 2 Of 5) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 63 Generic Electronic Module (Part 3 Of 5) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 64 Generic Electronic Module (Part 4 Of 5) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 65 Generic Electronic Module (Part 5 Of 5) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Page 66 General Module: Description and Operation GEM Circuit Protection Short Circuit/Battery Voltage The Generic Electronic Module (GEM) outputs are designed to withstand continuous exposure to a short circuit to ground or battery voltage without being damaged. GEM Feature and Functions The GEM controls the following features: ^ Wipers/washers (front/rear). ^ Warning chimes. ^ Battery saver. ^ Illuminated entry and courtesy lamps. ^ Driver power window. ^ Accessory delay. ^ 4-wheel drive. GEM Diagnostics The Generic Electronic Module (GEM) diagnostics are accessible with the New Generation STAR (NGS) tester and the Service Bay Diagnostic System (SBDS). The GEM constantly monitors its subsystems for concerns. If a concern is found in one of the subsystems, the GEM will record the concern in the form of a Diagnostic Trouble Code (DTC). There are three areas of diagnostic information useful when diagnosing the GEM. ^ DTCs - A record of past or present system problems. ^ PIDs - the present state of an input or output. ^ Active Commands - Gives the ability to turn on GEM outputs without activating the inputs normally associated with the function. Ignition Switch Positions The position of the ignition switch is very important to proper Generic Electronic Module (GEM) operation. Often times, erratic or unexpected operation can be traced to problems on these GEM inputs. The following is a brief description of five ignition switch positions. Run When the ignition switch is in this position, battery voltage should be present at the GEM RUN and RUN/ACC input terminals. Accessory (ACC) When the ignition switch is in this position, battery voltage should be present at the GEM RUN/ACC input terminal only. Start When the ignition switch is in this position, battery voltage should he present at the GEM start/clutch depressed input. Off and Lock The GEM does not have an OFF or LOCK Switch State input. The GEM will assume the OFF or LOCK position when there are no RUN, Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Page 67 ACC, or START signals present. Wiper/Washer Control and Interval Timer Front Wipers There are four modes of operation for the front wipers: speed dependent interval, slow, fast, and wash. These modes are only active with the ignition switch in the RUN or ACC position. Speed dependent wipers compensate for the extra moisture that accumulates on the windshield at higher speeds. At higher speeds, the speed dependent feature shortens the delay between wipes when using the variable interval wiper feature. Delays will automatically adjust at speeds between 16 and 105 kph (10 and 65 mph). Rear Wiper There are two modes of operation for the rear wipers, internal and wash. These modes are only active with the ignition switch in the RUN or ACC positions and both the liftgate and liftgate glass are closed. Chime Warning There are five warning chimes and lamps the Generic Electronic Module (GEM) controls: Headlights operating without the ignition ON (chime only), door ajar (chime and lamp), key in the ignition (chime only), driver seat belt warning (chime and lamp), and low washer fluid warning (chime and lamp). Battery Saver The battery saver feature removes extended interior lamp power drains from the battery. The Generic Electronic Module (GEM) will keep power available for all interior lights and under hood lamp circuits for 40 minutes after the ignition switch is turned OFF. The battery saver timer is reset by unlocking doors with remote entry key fob, activating a door ajar switch, or changing the ignition to RUN or ACC position. If asleep, the GEM will wake-up when: ^ Any door becomes ajar or is closed. ^ The key is inserted or removed. ^ The ignition switch is turned to ACC or RUN. ^ The doors are unlocked with the remote entry key fob. Courtesy Lamps/Illuminated Entry The Generic Electronic Module (GEM) illuminates the interior courtesy lamps when any door is ajar. The GEM also provides illuminated entry when the unlock button is used to unlock the vehicle. All interior courtesy lamps are turned OFF when any of the following occurs: ^ Twenty-five seconds have elapsed since the illuminated entry feature was activated and no door is ajar. ^ The ignition switch is turned to RUN and no door is ajar. ^ Vehicle speed is over 15 mph (a new ajar signal will turn on courtesy lamps only if the vehicle speed is less than 10 mph). ^ A power door lock command is received from the remote entry key fob and no door is ajar. Running Board Lamps The GEM illuminates the running board lamps when the interior lamps are activated and the ignition switch is not in the RUN position. Delayed Accessory (GEM only) The delayed accessory feature provides power to the power windows for ten minutes after the ignition switch is moved from the RUN to OFF position. If during this ten-minute period either front door is opened, the delayed accessory relay will be de-energized. One-Touch Window The power switch for the driver window control has two detents for the down window control. With the ignition switch in RUN or ACC, pressing the first detent (normal mode) allows manual down window control; pressing harder to the second detent (auto) will cause the driver window to automatically move to the full down position. Pressing either the up or down window switch will cancel an auto mode operation in progress. Transfer Case (Four Wheel Drive-GEM Only) This vehicle is equipped with Automatic 4-Wheel Drive (A4WD). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Flow of Diagnosis General Module: Flow of Diagnosis 1. Verify the customer's concern by operating the system in question. 2. Visually inspect for obvious signs of mechanical and electrical damage. Mechanical ^ Switch(es). Electrical ^ Fuse(s). ^ Circuit(s). ^ Damaged wiring harness(es). ^ Loose or damaged wires or connectors. 3. If the concern is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Flow of Diagnosis > Page 70 General Module: Initial Inspection and Diagnostic Overview 1. Verify the customer's concern by operating the system in question. 2. Visually inspect for obvious signs of mechanical and electrical damage. Mechanical ^ Switch(es). Electrical ^ Fuse(s). ^ Circuit(s). ^ Damaged wiring harness(es). ^ Loose or damaged wires or connectors. 3. If the concern is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Flow of Diagnosis > Page 71 General Module: Diagnostic Trouble Code Descriptions Part 1 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Flow of Diagnosis > Page 72 Part 2 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Flow of Diagnosis > Page 73 Part 3 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Flow of Diagnosis > Page 74 Part 4 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Flow of Diagnosis > Page 75 Part 5 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Flow of Diagnosis > Page 76 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Flow of Diagnosis > Page 77 General Module: Pinpoint Tests Pinpoint Test Icons Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. A: Cannot Communicate With the GEM Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Flow of Diagnosis > Page 78 A1-A2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Flow of Diagnosis > Page 79 A3-A4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Flow of Diagnosis > Page 80 A5-A6 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Flow of Diagnosis > Page 81 A7-A8 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Page 82 General Module: Service and Repair REMOVAL 1. Disconnect the positive or both battery cables. 2. Remove the cover from the instrument panel fuse junction panel. 3. Remove the lower instrument panel steering column cover. 1. Remove the six lower instrument panel steering column cover bolts. 2. Remove the lower instrument panel steering column cover. 4. Remove the two (A) bulkhead electrical connectors from the (B) instrument panel fuse junction panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Page 83 5. Remove the two (A) instrument panel fuse junction panel bolts and remove the two (B) interior fuse junction panel nuts. 6. Disconnect the three (A) GEM electrical connectors from the (B) GEM. 7. Remove the three GEM screws and the GEM. INSTALLATION 1. To install, reverse the removal procedure. Check for proper operation. 2. Install the lower instrument panel steering column cover. ^ Position the lower instrument panel steering column cover. ^ Install the six screws. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Page 84 General Module: Tools and Equipment Special Service Tool(s) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Specifications Keyless Entry Module: Specifications RAP Module Nuts ................................................................................................................................ ...................................................... 7 Nm (62.4 in lb) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Specifications > Page 88 Keyless Entry Module: Locations Body Views Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Specifications > Page 89 The Remote Anti-Theft Personality Module is located behind left side of instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Specifications > Page 90 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect the C257 and C256 Remote Anti-theft Personality (RAP) module electrical connectors. 2. Disconnect the antenna connector. 3. Remove the RAP module nuts and the RAP module. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Heated Mirror Relay > Component Information > Locations Heated Mirror Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Heated Mirror Relay > Component Information > Locations > Page 95 Junction Box Fuse/Relay Panel (Part 1 Of 2) The Heated Grid Relay is located in junction box fuse/relay panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Specifications Keyless Entry Module: Specifications RAP Module Nuts ................................................................................................................................ ...................................................... 7 Nm (62.4 in lb) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Specifications > Page 99 Keyless Entry Module: Locations Body Views Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Specifications > Page 100 The Remote Anti-Theft Personality Module is located behind left side of instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Specifications > Page 101 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect the C257 and C256 Remote Anti-theft Personality (RAP) module electrical connectors. 2. Disconnect the antenna connector. 3. Remove the RAP module nuts and the RAP module. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > All Lock Relay Power Door Lock Relay: Locations All Lock Relay Body View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 106 Lock Relays The All Lock Relay is located in lock relays. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 107 Power Door Lock Relay: Locations All Unlock Relay Body View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 108 Lock Relays The All Lock Relay is located in lock relays. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 109 Power Door Lock Relay: Locations Driver's Door Unlock Relay Body View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 110 Lock Relays The Driver's Unlock Relay is located in lock relays. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 111 Power Door Lock Relay: Locations Lock Relays Body View The Lock Relays are located behind right side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Relay > Component Information > Locations Sunroof / Moonroof Relay: Locations RPO Relay Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Relay > Component Information > Locations > Page 115 Instrument Panel View The Vent Window/Moonroof Relay is located in the regular production option (RPO) relay block which is located in the Dash, above the passenger air bag. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Relay > Component Information > Locations > Page 116 Sunroof / Moonroof Relay: Testing and Inspection Testing of an ISO relay can be accomplished through the use of three No. 10 (or larger gauge) jumper wires and a 73 Digital Multimeter. Remove (unplug) the relay to be tested from the engine compartment fuse junction panel, I/P fuse junction panel or individual connector. Mini ISO Relay Use the 73 Digital Multimeter to check for the continuity between terminal 85 and all other terminals. If resistance is 5 ohms or less between terminal 85 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay terminals 86 and 30 directly to the positive battery terminal. With the 73 Digital Multimeter set in the volts position, check for voltage at terminal 87A. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 85 and ground the jumper wire to a known good ground. Check for voltage at terminal 87. If battery voltage is not indicated, replace the relay. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations ABS Main Relay: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations > Page 121 Power Distribution Relay Box The 4 Wheel Anti-Lock Brake System Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 98-9-15 > May > 98 > ABS - Lamp ON/DTC B1342 Stored Electronic Brake Control Module: Customer Interest ABS - Lamp ON/DTC B1342 Stored Article No. 98-9-15 05/11/98 ^ BRAKES - 4WABS - ABS LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) B1342 STORED IN MEMORY AND/OR CODES NOT LISTED IN WORKSHOP MANUAL VEHICLES BUILT THROUGH 2/12/98 ^ LAMP - ABS LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) B1342 STORED IN MEMORY AND/OR CODES NOT LISTED IN WORKSHOP MANUAL - VEHICLES BUILT THROUGH 2/12/98 LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR ISSUE The Anti-lock Brake System (ABS) lamp may illuminate and Diagnostic Trouble Code (DTC) B1342 may be stored in memory and/or New Generation Star (NGS) Tester may read "Invalid Code." This may be caused by the Nonvolatile Random Access Memory (NVRAM) chip inside the anti-lock brake control module not resetting at low residual voltages. ABS brake function may become inoperative, however, normal braking operation will be maintained. ACTION Replace the anti-lock brake control module. Modules with a build date of 2/19/98 or later have been revised to incorporate a new NVRAM chip. Refer to the appropriate Workshop Manual, Section 206-09, for replacement procedures. PART NUMBER PART NAME F75Z-2C065-AA Anti-lock Brake Control Module (F-150) F75Z-20065-BA Anti-lock Brake Control Module (F-250 LD) F7SZ-2C065-CA Anti-lock Brake Control Module (Expedition, Navigator) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 980915A Diagnose And Replace 0.6 Hr. ABS Module - F-Series, Expedition, And Navigator DEALER CODING CONDITION BASIC PART NO. CODE 2C065 42 OASIS CODES: 206000, 301000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 98-9-15 > May > 98 > ABS - Lamp ON/DTC B1342 Stored Electronic Brake Control Module: All Technical Service Bulletins ABS - Lamp ON/DTC B1342 Stored Article No. 98-9-15 05/11/98 ^ BRAKES - 4WABS - ABS LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) B1342 STORED IN MEMORY AND/OR CODES NOT LISTED IN WORKSHOP MANUAL VEHICLES BUILT THROUGH 2/12/98 ^ LAMP - ABS LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) B1342 STORED IN MEMORY AND/OR CODES NOT LISTED IN WORKSHOP MANUAL - VEHICLES BUILT THROUGH 2/12/98 LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR ISSUE The Anti-lock Brake System (ABS) lamp may illuminate and Diagnostic Trouble Code (DTC) B1342 may be stored in memory and/or New Generation Star (NGS) Tester may read "Invalid Code." This may be caused by the Nonvolatile Random Access Memory (NVRAM) chip inside the anti-lock brake control module not resetting at low residual voltages. ABS brake function may become inoperative, however, normal braking operation will be maintained. ACTION Replace the anti-lock brake control module. Modules with a build date of 2/19/98 or later have been revised to incorporate a new NVRAM chip. Refer to the appropriate Workshop Manual, Section 206-09, for replacement procedures. PART NUMBER PART NAME F75Z-2C065-AA Anti-lock Brake Control Module (F-150) F75Z-20065-BA Anti-lock Brake Control Module (F-250 LD) F7SZ-2C065-CA Anti-lock Brake Control Module (Expedition, Navigator) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 980915A Diagnose And Replace 0.6 Hr. ABS Module - F-Series, Expedition, And Navigator DEALER CODING CONDITION BASIC PART NO. CODE 2C065 42 OASIS CODES: 206000, 301000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 135 Electronic Brake Control Module: Specifications TIGHTENING SPECIFICATIONS Control Module Screws .............................................................................................................................................................. 4-5 Nm (36-44 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 136 Electronic Brake Control Module: Locations Engine View The 4 Wheel Anti-Lock Brake System Module is located in the left side of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 137 Electronic Brake Control Module: Diagrams 4 Wheel Anti-Lock Brake System Module (C146) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 138 4 Wheel Anti-Lock Brake System Module (C147) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 139 Electronic Brake Control Module: Description and Operation COMPONENTS The Electronic Hydraulic Control Unit (EHCU) consists of the anti-lock brake control module and the hydraulic control unit (HCU). NOTE: The anti-lock brake control module can be replaced if it is inoperative. If the HCU is inoperative, the EHCU must be replaced as an assembly. PURPOSE The EHCU monitors the electromechanical components of the system. Malfunction of the anti-lock brake system will cause the EHCU to shut off or inhibit the system. However, normal power-assisted braking remains. Malfunctions are indicated by the yellow ABS warning indicator in the instrument cluster. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 140 Electronic Brake Control Module: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the two anti-lock brake control module electrical connectors. 3. Disconnect the pump motor electrica1 connector from the ABS module. 4. Remove the anti-lock brake control module. ^ Remove the screws. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 141 CAUTION: Ensure that the replacement anti-lock brake control module identification sticker reads EXP. Use of any other module could result in diminished ABS performance. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 146 Power Distribution Relay Box The Cooling Fan Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams Speed Control Servo/Amplifier Assembly Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 155 Power/Flasher Relay Block The Blower Relay is located in the blower/flasher relay block. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 156 Blower Motor Relay: Testing and Inspection Digital Multimeter Special Tools RELAY COMPONENT TEST Testing of an ISO relay can be accomplished through the use of three No. 10 (or larger gauge) jumper wires and a 73 Digital Multimeter. Remove (unplug) the relay to be tested from the engine compartment fuse junction panel, I/P fuse junction panel or individual connector. Mini ISO Relay Use 73 Digital Multimeter to check for the continuity between terminal 85 and all other terminals. If resistance is 5 ohms or less between terminal 85 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay terminals 86 and 30 directly to the positive battery terminal. With the multimeter set in the volts position, check for voltage at terminal 87A. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 85 and ground the jumper wire to a known good ground. Check for voltage at terminal 87. If battery voltage is not indicated, replace the relay. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 157 Blower Motor Relay: Tools and Equipment Digital Multimeter Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations As shown in the wiring diagrams, these vehicles do not use a compressor cut-off (also called a wide open throttle or WOT) relay. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Testing and Inspection Speedometer Module: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations Battery Discharge Protection Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 169 Junction Box Fuse/Relay Panel (Part 1 Of 2) The Battery Saver Relay is located in the junction box fuse/relay panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 170 Battery Discharge Protection Relay: Description and Operation The following components are controlled by the battery saver relay: - Interior lamps - Under hood lamp - Glove compartment lamp - Interior lamp relay - Accessory delay relay The battery saver relay becomes active (relay coil is energized) when the GEM is in the awake mode, and is deactivated (relay coil is de-energized) in the sleep mode. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations Courtesy Lamp Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations > Page 174 Junction Box Fuse/Relay Panel (Part 1 Of 2) The Interior Lamp Relay is located in junction box fuse/relay panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations > Page 175 Courtesy Lamp Relay: Description and Operation The Generic Electronic Module (GEM) controls the interior lamps illuminated entry function by activating the interior lamp relay. The relay is activated by applying ground to the relay coil through C267-15, and is deactivated by removing the ground signal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations Daytime Running Lamp Control Unit: Locations Engine View The Daytime Running Lamps Module is located at left front of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 179 Daytime Running Lamps Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Exterior Lighting Relay > Component Information > Locations Exterior Lighting Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Exterior Lighting Relay > Component Information > Locations > Page 184 RPO Relay Box The Park Lamp Relay is located in Regular Production Option relay block. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 188 Power Distribution Relay Box The Fog Lamp Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Locations Headlamp Control Module: Locations Instrument Panel View The Autolamp Module is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Locations > Page 192 Autolamp Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 196 RPO Relay Box The Autolamp Headlamp Relay is located in Regular Production Option relay block. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 200 Power Distribution Box The Horn Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations Interior Lighting Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 204 Junction Box Fuse/Relay Panel (Part 1 Of 2) The Interior Lamp Relay is located in junction box fuse/relay panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 205 Interior Lighting Relay: Description and Operation The Generic Electronic Module (GEM) controls the interior lamps illuminated entry function by activating the interior lamp relay. The relay is activated by applying ground to the relay coil through C267-15, and is deactivated by removing the ground signal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay Power Distribution Relay: Locations Trailer Tow Backup Lamp Relay Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 211 Power Distribution Relay Box The Trailer Tow Backup Lamp Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 212 Power Distribution Relay: Locations Trailer Tow Battery Charge Relay Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 213 Power Distribution Relay Box The Trailer Tow Battery Charge Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 214 Power Distribution Relay: Locations Trailer Tow Left Turn Relay Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 215 Power Distribution Relay Box The Trailer Tow Left Turn Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 216 Power Distribution Relay: Locations Trailer Tow Right Turn Relay Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 217 Power Distribution Relay Box The Trailer Tow Right Turn Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 218 Power Distribution Relay: Locations Trailer Tow Running Lamp Relay Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 219 Power Distribution Relay Box The Trailer Tow Running Lamp Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Blower/Flasher Relay Block Relay Box: Locations Blower/Flasher Relay Block Instrument Panel View The Blower/Flasher Relay Block is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Blower/Flasher Relay Block > Page 224 Relay Box: Locations Lock Relays Body View The Lock Relays are located behind right side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Blower/Flasher Relay Block > Page 225 Relay Box: Locations Regular Production Option Relay Block Instrument Panel View The Regular Production Option Relay Block is located in dash, above passenger air bag. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block Power/Flasher Relay Block Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 228 Lock Relays Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 229 Power Distribution Relay Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 230 RPO Relay Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures Engine Control Module: Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 237 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 238 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 239 Engine Control Module: Technical Service Bulletins PCM - Reprogramming Out of Vehicle Article No. 99-4-3 03/08/99 REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V VEHICLES ONLY FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97 PROBE 1996-99 CONTOUR, ESCORT, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to update the affected vehicles and to include an Application Chart for the affected vehicles. ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain reasonably priced, timely PCM programming services at dealerships. Ford has released an out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are reprogrammable to update calibration levels or to reprogram a common hardware type to a new calibration in order to fill a service need without ordering a new PCM. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 240 ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to have modules updated to new calibrations through the Parts Department instead of ordering new parts. Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the module. An aftermarket service center may bring a module to a dealership for a calibration update or may request an updated calibration be installed to a new service part. The EPA regulations require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a calibration on a PCM out of the vehicle. The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector. The proper calibration must be downloaded to the Data Transfer Card through Service Bay Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is connected, follow the calibration download instructions displayed on the NGS screen. The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling 1-800-ROTUNDA. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-26-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 206000, 290000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 241 Engine Control Module: Technical Service Bulletins PCM - Reprogramming Tips Article No. 97-9-8 04/28/97 POWERTRAIN CONTROL MODULE - REPROGRAM POWERTRAIN CONTROL MODULE (PCM) - SERVICE PROCEDURES - SERVICE TIP FORD: 1994-97 CROWN VICTORIA, MUSTANG, THUNDERBIRD 1996-97 CONTOUR, ESCORT, PROBE, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR, GRAND MARQUIS 1995-97 CONTINENTAL, TOWN CAR 1996-97 MARK VIII, MYSTIQUE, SABLE, TRACER LIGHT TRUCK: 1994-97 ECONOLINE, F-150-350 SERIES 1995-97 RANGER 1995-98 WINDSTAR 1996 BRONCO 1996-97 AEROSTAR, EXPLORER 1997 EXPEDITION, MOUNTAINEER This TSB article is being republished in its entirety to include Windstar. ISSUE: Powertrain Control Modules (PCMs) no longer need to be replaced when servicing driveability concerns. The only time a PCM needs replacing is when it can no longer be reprogrammed and/or is damaged. In all other cases, the PCM must be reprogrammed and NOT REPLACED. ACTION: Use the following Service Procedure to properly reprogram a PCM. SERVICE PROCEDURE PCM REPROGRAMMING USING SBDS 1. At the Main menu, select Powertrain and enter the Vehicle Identification Number (VIN). Select "Continue." 2. From the Powertrain menu, select Electronic Engine category. 3. Scroll through the "Tool List" to PCM Reprogramming and select "Continue." 4. Any TSBs or Recalls for the entered vehicle will be displayed. There is up to a 6 week delay for TSB/Recall information updates on SBDS. New TSBs/Recalls may not appear or only the TSB number will be displayed even though the new calibration is on the current calibration CD-ROM. Also, if the vehicle calibration is being updated because of a Special Service Message, Broadcast Message or the PCM was replaced and requires calibration, no screen may appear. This is not a concern and will not prevent programming updates or being paid for programming updates. 5. Follow all hook-up instructions and continue as prompted to the calibration screen. Typically, a list of calibration numbers will appear. Answer as appropriate for the vehicle and select "Continue." SBDS will then validate the information entered against the information read in the PCM, and any mismatch of software or hardware will be displayed for technician action. 6. Insert the proper calibration or the latest level CD-ROM when prompted and follow the instructions as displayed by SBDS. Do not crank the engine. SBDS will update the engine calibration to the latest level calibration for the selected calibration. 7. After programming is complete, SBDS will display a representation of the Authorized Modification Decal with the Engineering Part Number for the PCM installed. It is important that the label be completed and attached to the vehicle. S8DS will also automatically print a copy of the vehicle log for filing with the Repair Order. 8. Selecting "Continue" will call for a KOEO self test. Any hard faults present after performing self test were not caused by reprogramming. The calibration has now been validated and the PCM is operating properly. Unless directed by other Service Procedures, the vehicle can be released to Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 242 the customer. PCM REPROGRAMMING WITH SBTS/NGS 1. Select "NGS," then follow procedure "Touring PLM Recalibration." 2. Be sure to use cable with oversized DCL connector. The oversized connector incorporates an 18-volt transformer supplying the required voltage to reprogram the PCM. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-25-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 243 Engine Control Module: Specifications Powertrain Control Module Electrical Connector Bolt 5-7 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 244 Engine Control Module: Locations Engine View The Powertrain Control Module is located at right side of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 247 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 248 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 249 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 250 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 251 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 252 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 253 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 254 Engine Control Module: Connector Views Powertrain Control Module (Part 1 Of 3) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 255 Powertrain Control Module (Part 2 Of 3) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 256 Powertrain Control Module (Part 3 Of 3) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service Precautions > Electronic Component Handling Engine Control Module: Service Precautions Electronic Component Handling STATIC DISCHARGE - Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. - Never touch the PCM connector pins, integrated circuit connector pins, or soldered components on the PCM circuit board. TESTING - When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. - To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE - Do not try to disassemble the control unit. - Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, PCM and radio. - If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECUs. - Avoid getting water on any of the Fuel and Engine Control System Components. Never apply battery power to a component unless directed to do so in a test procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service Precautions > Electronic Component Handling > Page 259 Engine Control Module: Service Precautions Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. PCM memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service Precautions > Electronic Component Handling > Page 260 Engine Control Module: Service Precautions Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service Precautions > Page 261 Engine Control Module: Description and Operation OVERVIEW The Electronic Engine Control (EEC) system provides optimum control of the engine and transmission through the enhanced capability of the Powertrain Control Module (PCM). The EEC system also has an On-board Diagnostics (OBDII) monitoring system with features and functions to meet federal regulations on exhaust emissions. COMPONENTS The EEC system has two major divisions: hardware and software. The hardware includes the PCM, Natural Gas Vehicle (NGV) Module, Constant Control Relay Module (CCRM), Variable Load Control Module (VLCM), sensors, switches, actuators, solenoids, and interconnecting terminals. The software in the PCM provides the strategy control for outputs (engine hardware) based on the values of the inputs to the PCM. OPERATION The PCM receives information from a variety of sensor and switch inputs. Based on the strategy and calibration stored within the memory chip, the PCM generates the appropriate output. The system is designed to minimize emissions and optimize fuel economy and driveability. The software strategy controls the basic operation of the engine and transmission, provides the OBD II strategy, controls the Malfunction Indicator Lamp (MIL), communicates to the scan tool [New Generation Star (NGS), etc.] via the Data Link Connector (DLC), allows for Flash Electrically Erasable/ Programmable Read Only Memory (FEEPROM), provides idle air and fuel trim, and controls Failure Mode Effects Management (FMEM). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Reset Procedure Engine Control Module: Reset Procedure Description The Powertrain Control Module (PCM) Reset allows the scan tool to command the PCM to clear all emission-related diagnostic information. When resetting the PCM, a DTC P1000 will be stored in the PCM until all the OBD II system monitors or components have been tested to satisfy a drive cycle, without any other faults occurring. The following events occur when a PCM reset is performed: - Clears the number of Diagnostic Trouble Codes (DTCs). - Clears the DTCs. - Clears the freeze frame data. - Clears oxygen sensor test data. - Resets status of the OBD II system monitors. - Sets DTC P1000. New Generation STAR (NGS) and Generic Scan Tool Refer to the manufacturer's manual for specific instructions on how to perform PCM reset. Resetting Keep Alive Random Access Memory (RAM) Disconnect the battery ground cable for a minimum of 5 minutes. Resetting Keep Alive RAM will clear learned values the PCM has stored for adaptive systems such as idle and fuel trim. After Keep Alive RAM has been reset, the vehicle may exhibit certain driveability concerns. It will be necessary to drive the vehicle to allow the PCM to relearn values for optimum driveability and performance. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Reset Procedure > Page 264 Engine Control Module: Removal and Replacement REMOVAL 1. Remove the battery and battery tray. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Loosen the PCM electrical connector bolt and separate the PCM electrical connectors. 3. Remove the RH front door scuff plate. 4. Remove the RH cowl side trim panel. 5. Release the PCM bracket clip. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Reset Procedure > Page 265 6. Remove the PCM. INSTALLATION To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 269 Power Distribution Box The Powertrain Control Module (EEC) Power Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 274 Power Distribution Box The Fuel Pump Relay is located in the LH front of engine compartment, in the Power Distribution box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 278 Power Distribution Box The Powertrain Control Module (EEC) Power Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Locations Ignition Control Module: Locations The ignition control module is integrated within the powertrain control module. It is not a separately replaceable component. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Locations > Page 283 Ignition Control Module: Description and Operation PURPOSE - The Ignition Control Module (ICM) is incorporated within the Powertrain Control Module (PCM). The ICM receives engine position and speed information from within the crankshaft position sensor and desired spark advance information from the PCM. OPERATION - The ICM synthesizes a profile ignition pick up signal and ignition diagnostic monitor signal for use within The PCM. - The PCM uses this information to determine which ignition coil to fire, calculating the turn ON/OFF times of the ignition coil required to achieve the correct dwell and spark advance. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications Air Bag Control Module: Specifications Air Bag Diagnostic Monitor Screws ...................................................................................................................................... 10.2-13.8 Nm (91-123 lb in) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 288 Air Bag Control Module: Locations Instrument Panel View The Air Bag Diagnostic Monitor is located behind right side (Passenger Side) of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 289 Air Bag Control Module: Diagrams Air Bag Diagnostic Monitor (C208) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 290 Air Bag Diagnostic Monitor (C209) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 291 Air Bag Control Module: Service Precautions WARNING: Under no circumstances substitute another fuse value for the 10 AMP battery fuse. Any fuse other than 10 AMP may cause disarming failure and may result in danger to the occupants of the vehicle. Do not attempt to replace the 10 AMP battery fuse until the air bag system first has been deactivated . Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 292 Air Bag Control Module: Description and Operation PURPOSE Performing system diagnostics is the main purpose of the air bag diagnostic monitor. The air bag diagnostic monitor continually monitors all air bag system components and wiring connections for possible faults when the ignition switch is in RUN position. OPERATION It does not deploy the air bags in the event of a collision. The air bag diagnostic monitor operates in the following manner: - If the air bag diagnostic monitor detects a fault in the air bag system, a Diagnostic Trouble Code (DTC) will be written to the air bag diagnostic monitor's Non-Volatile Random Access Memory (NVRAM). - This DTC will then be displayed on the air bag indicator lamp. - After servicing, the DTC may then be cleared from NVRAM. AIR BAG SYSTEM FUNCTIONS Other important features of the air bag diagnostic monitor and its functions within the system are described below. It is necessary that these key features and functions are well understood. - The air bag diagnostic monitor illuminates the air bag indicator for approximately six seconds when the ignition switch is in the RUN position and then turns the indicator off. This shows that the air bag indicator is operational. If the air bag indicator does not illuminate or the indicator stays on or flashes at any time, a fault has been detected by the air bag diagnostic monitor. - DTCs may not be displayed for approximately 30 seconds after the ignition switch is placed in the RUN position. This is the amount of time the air bag diagnostic monitor requires to perform all tests and verify system faults, if present. - Each diagnostic trouble code (a series of flashes and pauses of the air bag indicator) represents a two digit number. Each diagnostic trouble code is always displayed at least twice. For example, a diagnostic trouble code 32 is displayed as three flashes, followed by a one second pause, then two flashes, followed by a three second pause. - If a system fault is present and the air bag indicator is malfunctioning, an audible tone will be heard, indicating that system service is required. CAUTION: The thermal fuse does not blow (open) because of excessive current flowing through it. Do not attempt to jumper out the thermal fuse with a circuit breaker or any other type of fuse. - If a fault exists that makes unwanted air bag deployment possible, the air bag diagnostic monitor will attempt to remove deployment power by turning on a solid state switch to blow the 10A battery fuse 2. - If the 10 A battery fuse has successfully been blown by the air bag diagnostic monitor, the air bag diagnostic monitor will not attempt to blow it again until the proper fault has been repaired and cleared (see Diagnostic Trouble Code Clearing procedures for details). The air bag diagnostic monitor will store both the unwanted deployment DTC and the loss of deployment power DTC. The loss of deployment power DTC is the highest priority. - Diagnostic trouble codes are prioritized numerically so if two or more different faults occur at the same time, the fault having the highest priority will be displayed first. After that fault has been corrected, the next highest priority fault will be displayed. - The air bag diagnostic monitor includes an internal backup power supply. This feature provides sufficient backup power to deploy the air bag in the event that the battery or battery cables are damaged in an accident before the center air bag and front air bag sensors close. The backup power supply will deplete its stored energy approximately one minute after the positive battery cable is disconnected. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 293 Air Bag Control Module: Service and Repair REMOVAL WARNING: To avoid accidental deployment and possible injury, the backup power supply must be depleted before repairing or replacing any air bag system components. To deplete the backup power supply energy, disconnect the battery to starter relay cable and wait one minute. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: The safing sensor is internal to the air bag diagnostic monitor and is not replaced separately. 1. Disconnect the battery cables. 2. Remove the RH cowl side trim panel. 3. Remove the air bag diagnostic monitor. 1 Disconnect the two electrical connectors. 2 Remove the four screws. 3 Remove the air bag diagnostic monitor. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Warning Relay > Component Information > Description and Operation Seat Belt Warning Relay: Description and Operation The driver safety belt incorporates a safety belt warning indicator switch, warning indicator and chime. The warning indicator and chime are reminders to fasten the safety belt. - If the safety belt is not buckled when the key is turned to the ON position, the warning indicator and chime will turn on for 4 to 8 seconds. - If the safety belt is buckled while the warning indicator is on and the chime is sounding, both the warning indicator and chime will turn off. - If the safety belt is buckled before the key is turned to the ON position, the warning indicator will come on for 4 to 8 seconds with no chime. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Engine View The Starter Motor Relay is located at right rear of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 301 Starter Relay: Description and Operation The starter motor solenoid relay switch: - Controls current to the starter solenoid. - Is engaged by the ignition switch. - Connects the battery to the starter motor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Steering > Steering Control Module > Component Information > Locations Steering Control Module: Locations Instrument Panel View The Electronic Variable Orifice Module is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Steering > Steering Control Module > Component Information > Locations > Page 307 Electronic Variable Orifice Steering Module (Without Air Suspension) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations Compressor/Pump Relay: Locations Engine View The Air Suspension Compressor Relay is located near the right headlamp. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 312 Compressor/Pump Relay: Description and Operation A Solid State Relay is used in the air suspension system for compressor control. The relay incorporates a custom power MOSFET and ceramic hybrid circuitry. The relay switches high current loads in response to low power signals and is controlled by the logic of the control module. The compressor relay is energized by the control module to have high current flow from the battery to the compressor motor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Technical Service Bulletin # 01-12-8 Date: 010625 Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Article No. 01-12-8 06/25/01 ^ SUSPENSION - AIR SUSPENSION - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE ^ ELECTRICAL - LAMP - AIR SUSPENSION LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE FORD: 1997-2001 EXPEDITION LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit a check suspension lamp ON with Diagnostic Trouble Codes (DTC's) B2140 or C2140 even after the Air Suspension switch in the upper RH kick panel has been turned on. This may occur at pre-delivery, following suspension service, or after Air Suspension module replacement. This may be caused by the ride height calibration. ACTION Adjust and/or recalibrate ride height as necessary using the NGS (New Generation Star) Tester. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011208A Recalibrate Ride Height 0.2 Hr. For Rear Air Suspension (R.A.S.) 4X2 Vehicles Only 011208B Recalibrate Ride Height 0.5 Hr. For 4 Wheel Air Suspension (4W.A.S.) (Includes Time To Adjust Torsion Bars 4X4 Vehicles Only) DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000, 390000 Service Procedure NOTE DURING PDI (PRE-DELIVERY INSPECTION) IF "CK SUSP" LIGHT IS ON, PRIOR TO SENDING TO SERVICE, VERIFY SWITCH IN UPPER RIGHT KICK PANEL IS ON. THIS SWITCH IS TURNED OFF DURING VEHICLE SHIPMENT TO PREVENT MODULE FROM SEEKING TRIM HEIGHT WHILE SECURED DOWN FOR TRANSPORT. NOTE AN INADVERTENT B2140 OR C2140 MAY RESULT IF A PARAMETER RESET (CLEAR RIDE HEIGHT) IS SELECTED UNDER NGS ACTIVE COMMANDS, THEN CANCELLED OUT. NOTE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 321 THE AIR SUSPENSION CONTROL MODULE PART NUMBER IS INTERCHANGEABLE BETWEEN THE REAR AIR SUSPENSION (RAS) AND 4-WHEEL AIR SUSPENSION (4WAS) SYSTEMS, BUT ONCE THE MODULE IS INSTALLED, THE VEHICLE WILL THEN DETERMINE WHETHER VEHICLE IS 4X2 (RAS) OR 4X4 (4WAS) BASED ON VEHICLE HARNESS INPUTS. NOTE MODULES ARE PRE-PROGRAMMED TO SEEK 2.66 VOLTS + 1.02 VOLTS FROM REAR HEIGHT SENSOR (RHGSTEN PARAMETER IDENTIFIER OR PID) AT TRIM HEIGHT. HOWEVER, A NEW OR SWAPPED MODULE REQUIRES CALIBRATION PER STEPS BELOW TO CLEAR A 2140 (INITIALIZATION FAILURE) CODE. NOTE PERFORM 4WAS-AIR SUSP/EVO (ELECTRONIC VARIABLE ORIFICE STEERING) SELF TEST AND MAKE NECESSARY REPAIRS FOR ANY OTHER AIR SUSPENSION DTC'S THAT ARE PRESENT BEFORE ADDRESSING B2140/C2140. WARNING WARNING: BEFORE REPLACING ANY AIR SUSPENSION COMPONENTS, HOISTING, JACKING, OR TOWING, DISCONNECT POWER TO THE SYSTEM BY, TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RIGHT KICK PANEL AREA TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. RAS ONLY - CLEAR 2140 NOTE EVEN RAS (4X2) EQUIPPED VEHICLES REQUIRE STORING RIDE HEIGHT AND TOGGLING FRONT TO "ON" TO CLEAR A CK SUSP LIGHT/214O CODE. THIS ALLOWS THE MODULE TO STORE THE VOLTAGE WITH NO FRONT HEIGHT SENSOR PRESENT, AND MUST BE DONE EVEN WITH CONVENTIONAL (STEEL COIL) FRONT SUSPENSION. 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON", press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step # 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional (on-demand) test is in process. As test completes, verify a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off. 4WAS - CLEAR 2140 DTC - Mechanical NOTE OBSERVE AND REPAIR ANY DAMAGED PARTS OR SYSTEM LEAKS, INSPECTING THE AIR LINE UNION LOCATED UNDER THE BRAKE MASTER CYLINDER FIRST. IF BRAKE FLUID HAS DAMAGED THE LINE, REPLACE THEN REROUTE NEW AIR LINE AWAY FROM AN ORIENTATION DIRECTLY UNDER THE MASTER CYLINDER. BRUSH A SOAPY WATER SOLUTION ON REMAINING SYSTEM CONNECTIONS, INCLUDING INLINE AND "T" UNIONS; AIR LINE RUB POINTS; COMPRESSOR FITTINGS; GATE AND FILL SOLENOIDS; AND AIR SHOCKS/SPRINGS. KEEP IN MIND THAT AIR SPRING LEAKS WHERE THE BAG FOLDS OVER ITSELF MAY NOT BE IMMEDIATELY OBVIOUS WITHOUT CYCLING THE SUSPENSION THROUGH DIFFERENT HEIGHTS. IF AIR BUBBLES ARE DETECTED, REPAIR AS NECESSARY THEN RETEST TO ENSURE LEAK-FREE CONNECTIONS BEFORE COMPLETING THE STEPS BELOW. 1. Bring the vehicle to kneel height by turning ignition key off, gear lever in park, doors closed for up to 30 seconds on level ground. Listen for compressor's vent solenoid to release air from lines before proceeding. Venting should occur within approximately one minute of closing all doors Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 322 with the key in the "off" position. 2. Erase the module's memory: ^ Trigger 4WAS active commands, PARAMETER RESET (Clear Ride Height) WARNING DO NOT RESET REAR HEIGHT AT THIS TIME! ^ Trigger thru warning message, then toggle FRONT CLR from "OFF" to "ON" Press Cancel NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION! 3. You have now cleared the front kneel voltage stored in the module and B2140 will be present on next key-up. 4. Bleed air from front shocks: ^ Mark existing torsion bar setting, then back off the torsion bar adjustment bolt several turns (until approximately 40 mm (1.5") distance from the bolt head to the bottom surface of the torsion bar adjuster is reached) ^ Select AIR SUSP CNTRL from active command menu (NGS will return to this after previous steps) ^ Trigger VENT FRONT, then wait several seconds for air to vent. Press Cancel to exit. 5. Adjust torsion bars per Workshop Manual section 204-01B. NOTE LEAVE THE NGS CONNECTED IN ACTIVE COMMAND MODES (ENTERED IN STEP 4) 50 THE SYSTEM REMAINS IN DIAGNOSTIC MODE AND NOT OPERATIONAL MODE. 6. Finish by performing the following electrical front height reset steps. 4WAS - CLEAR 2140 DTC - Electrical 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON". press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional on-demand test is in process. As test completes, verity a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off and vehicle height settles out as compressor fills air bladders/shocks. NOTE FOR OTHER AIR SUSPENSION CONCERNS, REFER TO THE APPROPRIATE WORKSHOP MANUAL SECTIONS: 204-05A FOR VEHICLE DYNAMIC SUSPENSION - REAR, OR SECTION 204-05B FOR VEHICLE DYNAMIC SUSPENSION - 4 WHEEL. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 98-25-4 > Dec > 98 > Suspension - Warning Lamp ON/DTC's C1770/C1845 Suspension Control Module: Customer Interest Suspension - Warning Lamp ON/DTC's C1770/C1845 Article No. 98-25-4 12/21/98 SUSPENSION - CHECK SUSPENSION LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) C1770 AND/OR C1845 STORED IN MEMORY - VEHICLES BUILT THROUGH 10/1/1998 LIGHT TRUCK: 1997-99 EXPEDITION 1998-99 NAVIGATOR ISSUE Some vehicles equipped with air suspension may exhibit an intermittent check suspension lamp on and Diagnostic Trouble Code (DTC) C1770 and/or C1845 illuminated. Vehicles with these codes may not exhibit any ride height concerns. This may be caused by the air suspension control module. ACTION Replace the air suspension control module with a revised air suspension control module and recalibrate ride height. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Connect New Generation Star (NGS) Tester and go to Air Suspension menu to retrieve stored codes. Confirm that you have code C1770 and/or C1845 in memory. If you have any other codes, proceed with appropriate pinpoint tests in the 1998 Expedition/Navigator Workshop Manual, Section 204-OSA (Rear) or 204-05B (4-Wheel). 2. With NGS Tester, run the air suspension On-Demand self test. If you have any codes, proceed with appropriate pinpoint tests in the Workshop Manual, Section 204-OSA or 204-05B. 3. With NGS Tester, select Active Command Modes menu and manually raise and lower vehicle per Ride Height Adjustment procedure, 1998 Workshop Manual, Section 204-OSA or 204-05B. Monitor vehicle height changes. If vehicle does not respond, follow pinpoint tests for pneumatic failures. If vehicle does function properly, continue with Step 4. 4. Replace air suspension control module per the 1998 Workshop Manual, Section 204-OSA or 204-05B. NOTE A NEW OR EXCHANGED AIR SUSPENSION CONTROL MODULE REQUIRES THAT THE RIDE HEIGHT ADJUSTMENT CALIBRATION PROCESS BE PERFORMED; REFER TO FRONT RIDE HEIGHT RESETTING-CLEAR B2140 DTC. PART NUMBER PART NAME F7SZ-5A919-DB Air Suspension Module (1997-98) XL1Z-5A919-AA Air Suspension Module (1999) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982504A Perform Diagnostics, Install 1.2 Hrs. Air Suspension Module, And Perform Ride Height Adjustment Calibration Process DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Technical Service Bulletin # 01-12-8 Date: 010625 Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Article No. 01-12-8 06/25/01 ^ SUSPENSION - AIR SUSPENSION - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE ^ ELECTRICAL - LAMP - AIR SUSPENSION LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE FORD: 1997-2001 EXPEDITION LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit a check suspension lamp ON with Diagnostic Trouble Codes (DTC's) B2140 or C2140 even after the Air Suspension switch in the upper RH kick panel has been turned on. This may occur at pre-delivery, following suspension service, or after Air Suspension module replacement. This may be caused by the ride height calibration. ACTION Adjust and/or recalibrate ride height as necessary using the NGS (New Generation Star) Tester. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011208A Recalibrate Ride Height 0.2 Hr. For Rear Air Suspension (R.A.S.) 4X2 Vehicles Only 011208B Recalibrate Ride Height 0.5 Hr. For 4 Wheel Air Suspension (4W.A.S.) (Includes Time To Adjust Torsion Bars 4X4 Vehicles Only) DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000, 390000 Service Procedure NOTE DURING PDI (PRE-DELIVERY INSPECTION) IF "CK SUSP" LIGHT IS ON, PRIOR TO SENDING TO SERVICE, VERIFY SWITCH IN UPPER RIGHT KICK PANEL IS ON. THIS SWITCH IS TURNED OFF DURING VEHICLE SHIPMENT TO PREVENT MODULE FROM SEEKING TRIM HEIGHT WHILE SECURED DOWN FOR TRANSPORT. NOTE AN INADVERTENT B2140 OR C2140 MAY RESULT IF A PARAMETER RESET (CLEAR RIDE HEIGHT) IS SELECTED UNDER NGS ACTIVE COMMANDS, THEN CANCELLED OUT. NOTE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 332 THE AIR SUSPENSION CONTROL MODULE PART NUMBER IS INTERCHANGEABLE BETWEEN THE REAR AIR SUSPENSION (RAS) AND 4-WHEEL AIR SUSPENSION (4WAS) SYSTEMS, BUT ONCE THE MODULE IS INSTALLED, THE VEHICLE WILL THEN DETERMINE WHETHER VEHICLE IS 4X2 (RAS) OR 4X4 (4WAS) BASED ON VEHICLE HARNESS INPUTS. NOTE MODULES ARE PRE-PROGRAMMED TO SEEK 2.66 VOLTS + 1.02 VOLTS FROM REAR HEIGHT SENSOR (RHGSTEN PARAMETER IDENTIFIER OR PID) AT TRIM HEIGHT. HOWEVER, A NEW OR SWAPPED MODULE REQUIRES CALIBRATION PER STEPS BELOW TO CLEAR A 2140 (INITIALIZATION FAILURE) CODE. NOTE PERFORM 4WAS-AIR SUSP/EVO (ELECTRONIC VARIABLE ORIFICE STEERING) SELF TEST AND MAKE NECESSARY REPAIRS FOR ANY OTHER AIR SUSPENSION DTC'S THAT ARE PRESENT BEFORE ADDRESSING B2140/C2140. WARNING WARNING: BEFORE REPLACING ANY AIR SUSPENSION COMPONENTS, HOISTING, JACKING, OR TOWING, DISCONNECT POWER TO THE SYSTEM BY, TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RIGHT KICK PANEL AREA TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. RAS ONLY - CLEAR 2140 NOTE EVEN RAS (4X2) EQUIPPED VEHICLES REQUIRE STORING RIDE HEIGHT AND TOGGLING FRONT TO "ON" TO CLEAR A CK SUSP LIGHT/214O CODE. THIS ALLOWS THE MODULE TO STORE THE VOLTAGE WITH NO FRONT HEIGHT SENSOR PRESENT, AND MUST BE DONE EVEN WITH CONVENTIONAL (STEEL COIL) FRONT SUSPENSION. 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON", press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step # 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional (on-demand) test is in process. As test completes, verify a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off. 4WAS - CLEAR 2140 DTC - Mechanical NOTE OBSERVE AND REPAIR ANY DAMAGED PARTS OR SYSTEM LEAKS, INSPECTING THE AIR LINE UNION LOCATED UNDER THE BRAKE MASTER CYLINDER FIRST. IF BRAKE FLUID HAS DAMAGED THE LINE, REPLACE THEN REROUTE NEW AIR LINE AWAY FROM AN ORIENTATION DIRECTLY UNDER THE MASTER CYLINDER. BRUSH A SOAPY WATER SOLUTION ON REMAINING SYSTEM CONNECTIONS, INCLUDING INLINE AND "T" UNIONS; AIR LINE RUB POINTS; COMPRESSOR FITTINGS; GATE AND FILL SOLENOIDS; AND AIR SHOCKS/SPRINGS. KEEP IN MIND THAT AIR SPRING LEAKS WHERE THE BAG FOLDS OVER ITSELF MAY NOT BE IMMEDIATELY OBVIOUS WITHOUT CYCLING THE SUSPENSION THROUGH DIFFERENT HEIGHTS. IF AIR BUBBLES ARE DETECTED, REPAIR AS NECESSARY THEN RETEST TO ENSURE LEAK-FREE CONNECTIONS BEFORE COMPLETING THE STEPS BELOW. 1. Bring the vehicle to kneel height by turning ignition key off, gear lever in park, doors closed for up to 30 seconds on level ground. Listen for compressor's vent solenoid to release air from lines before proceeding. Venting should occur within approximately one minute of closing all doors Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 333 with the key in the "off" position. 2. Erase the module's memory: ^ Trigger 4WAS active commands, PARAMETER RESET (Clear Ride Height) WARNING DO NOT RESET REAR HEIGHT AT THIS TIME! ^ Trigger thru warning message, then toggle FRONT CLR from "OFF" to "ON" Press Cancel NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION! 3. You have now cleared the front kneel voltage stored in the module and B2140 will be present on next key-up. 4. Bleed air from front shocks: ^ Mark existing torsion bar setting, then back off the torsion bar adjustment bolt several turns (until approximately 40 mm (1.5") distance from the bolt head to the bottom surface of the torsion bar adjuster is reached) ^ Select AIR SUSP CNTRL from active command menu (NGS will return to this after previous steps) ^ Trigger VENT FRONT, then wait several seconds for air to vent. Press Cancel to exit. 5. Adjust torsion bars per Workshop Manual section 204-01B. NOTE LEAVE THE NGS CONNECTED IN ACTIVE COMMAND MODES (ENTERED IN STEP 4) 50 THE SYSTEM REMAINS IN DIAGNOSTIC MODE AND NOT OPERATIONAL MODE. 6. Finish by performing the following electrical front height reset steps. 4WAS - CLEAR 2140 DTC - Electrical 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON". press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional on-demand test is in process. As test completes, verity a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off and vehicle height settles out as compressor fills air bladders/shocks. NOTE FOR OTHER AIR SUSPENSION CONCERNS, REFER TO THE APPROPRIATE WORKSHOP MANUAL SECTIONS: 204-05A FOR VEHICLE DYNAMIC SUSPENSION - REAR, OR SECTION 204-05B FOR VEHICLE DYNAMIC SUSPENSION - 4 WHEEL. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 98-25-4 > Dec > 98 > Suspension - Warning Lamp ON/DTC's C1770/C1845 Suspension Control Module: All Technical Service Bulletins Suspension - Warning Lamp ON/DTC's C1770/C1845 Article No. 98-25-4 12/21/98 SUSPENSION - CHECK SUSPENSION LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) C1770 AND/OR C1845 STORED IN MEMORY - VEHICLES BUILT THROUGH 10/1/1998 LIGHT TRUCK: 1997-99 EXPEDITION 1998-99 NAVIGATOR ISSUE Some vehicles equipped with air suspension may exhibit an intermittent check suspension lamp on and Diagnostic Trouble Code (DTC) C1770 and/or C1845 illuminated. Vehicles with these codes may not exhibit any ride height concerns. This may be caused by the air suspension control module. ACTION Replace the air suspension control module with a revised air suspension control module and recalibrate ride height. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Connect New Generation Star (NGS) Tester and go to Air Suspension menu to retrieve stored codes. Confirm that you have code C1770 and/or C1845 in memory. If you have any other codes, proceed with appropriate pinpoint tests in the 1998 Expedition/Navigator Workshop Manual, Section 204-OSA (Rear) or 204-05B (4-Wheel). 2. With NGS Tester, run the air suspension On-Demand self test. If you have any codes, proceed with appropriate pinpoint tests in the Workshop Manual, Section 204-OSA or 204-05B. 3. With NGS Tester, select Active Command Modes menu and manually raise and lower vehicle per Ride Height Adjustment procedure, 1998 Workshop Manual, Section 204-OSA or 204-05B. Monitor vehicle height changes. If vehicle does not respond, follow pinpoint tests for pneumatic failures. If vehicle does function properly, continue with Step 4. 4. Replace air suspension control module per the 1998 Workshop Manual, Section 204-OSA or 204-05B. NOTE A NEW OR EXCHANGED AIR SUSPENSION CONTROL MODULE REQUIRES THAT THE RIDE HEIGHT ADJUSTMENT CALIBRATION PROCESS BE PERFORMED; REFER TO FRONT RIDE HEIGHT RESETTING-CLEAR B2140 DTC. PART NUMBER PART NAME F7SZ-5A919-DB Air Suspension Module (1997-98) XL1Z-5A919-AA Air Suspension Module (1999) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982504A Perform Diagnostics, Install 1.2 Hrs. Air Suspension Module, And Perform Ride Height Adjustment Calibration Process DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Locations > Electronic Level Control (ELC) Module Suspension Control Module: Locations Electronic Level Control (ELC) Module Instrument Panel View The 4 Wheel Air-Suspension Module is located behind the center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Locations > Electronic Level Control (ELC) Module > Page 340 Suspension Control Module: Locations Suspension Control Module Instrument Panel View The 4 Wheel Air-Suspension Module is located behind the center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Diagrams > Electronic Level Control (ELC) Module Suspension Control Module: Diagrams Electronic Level Control (ELC) Module 4 Wheel Air Suspension Module (C295) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Diagrams > Electronic Level Control (ELC) Module > Page 343 4 Wheel Air Suspension Module (C296) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Diagrams > Electronic Level Control (ELC) Module > Page 344 Suspension Control Module: Diagrams Suspension Control Module 4 Wheel Air Suspension Module (C295) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Diagrams > Electronic Level Control (ELC) Module > Page 345 4 Wheel Air Suspension Module (C296) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Description and Operation > Four Wheel Air Suspension Suspension Control Module: Description and Operation Four Wheel Air Suspension A microcontroller-based electronic module controls the air compressor motor (through a solid state relay), and all system solenoids. The module also provides power to front and rear height sensors. The module controls vehicle height adjustments by monitoring the two height sensors, vehicle speed, a steering sensor, acceleration input, the door ajar signal, transfer case signals, and the brake switch. The module also conducts all fail-safe and diagnostic strategies and contains self-test and communication software for testing of the vehicle and related components. The control module is mounted in the passenger compartment inside the instrument panel, above the radio and temperature controls. The air suspension system control module monitors and controls the system through a 32-pin two-way connector. The control module is keyed so that it cannot be plugged into an incorrect harness. There are two sides of the harness connection to the module. Each is uniquely colored and keyed to prevent reversing the connections. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Description and Operation > Four Wheel Air Suspension > Page 348 Suspension Control Module: Description and Operation Rear Air Suspension A microcontroller-based electronic module controls the air compressor motor (through a solid state relay), and all system solenoids. The module also provides power to the rear height sensor. The module controls vehicle height adjustments by monitoring the one height sensor, vehicle speed, a steering sensor, acceleration input, the door ajar signal, transfer case signals, and the brake switch. The module also conducts all fail-safe and diagnostic strategies and contains self-test and communication software for testing of the vehicle and related components. The control module is mounted in the passenger compartment inside the instrument panel, above the radio and temperature controls. The air suspension system control module monitors and controls the system through a 32-pin two-way connector. The control module is keyed so that it cannot be plugged into an incorrect harness. There are two sides of the harness connection to the module. Each is uniquely colored and keyed to prevent reversing the connections. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Service and Repair > Four Wheel Air Suspension Suspension Control Module: Service and Repair Four Wheel Air Suspension REMOVAL 1. Disconnect battery ground cable. 2. Remove the center instrument panel finish panel. 4 3. Disconnect the transfer case rotary control switch electrical connector. 4. Remove the steering column cover trim panel. 5. Remove the headlamp switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Service and Repair > Four Wheel Air Suspension > Page 351 6. Remove the LH instrument panel finish panel. (1) Remove the screws. (2) Remove the instrument panel finish panel. 7. Remove the instrument cluster panel. (1) Remove the screws. (2) Remove the instrument cluster panel. 8. Remove the control module mounting bracket screws. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Service and Repair > Four Wheel Air Suspension > Page 352 9. Lift control module and mounting bracket from instrument panel and disconnect the control module electrical connectors. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Service and Repair > Four Wheel Air Suspension > Page 353 Suspension Control Module: Service and Repair Rear Air Suspension REMOVAL 1. Disconnect battery ground cable. 2. Remove the center instrument panel finish panel. 3. Remove the steering column cover trim panel. 4. Remove the headlamp switch. 5. Remove the LH instrument panel finish panel. (1) Remove the screws. (2) Remove the instrument panel finish panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Service and Repair > Four Wheel Air Suspension > Page 354 6. Remove the instrument chaster panel. (1) Remove the screws. (2) Remove the instrument cluster panel. 7. Remove the control module mounting bracket screws. 8. Lift the control module and mounting bracket from the instrument panel and disconnect the control module electrical connectors. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque On Demand Relay Four Wheel Drive Selector Relay: Locations Torque On Demand Relay Instrument Panel View The Torque On Demand Relay is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque On Demand Relay > Page 361 Four Wheel Drive Selector Relay: Locations Transfer Case Shift Relay Instrument Panel View The Transfer Case Shift Relays are located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Torque On Demand Relay Torque On Demand Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Torque On Demand Relay > Page 364 Transfer Case Shift Relays Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 369 Junction Box Fuse/Relay Panel (Part 1 Of 2) The Heated Grid Relay is located in junction box fuse/relay panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations Power Window Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Page 373 Junction Box Fuse/Relay Panel (Part 1 Of 2) The One Touch Down Relay is located in the junction box fuse/relay panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Page 374 Power Window Relay: Description and Operation The GEM controls manual down and auto down window movement with the down window relay. The relay is activated by applying ground directly to one side of the down window relay coil, and deactivated by removing the ground signal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Page 375 Power Window Relay: Testing and Inspection 73 Digital Multimeter Special Tool(s) Testing of an ISO relay can be accomplished through the use of three No. 10 (or larger gauge) jumper wires and 73 Digital Multimeter. Remove (unplug) the relay to be tested from the engine compartment fuse junction panel, I/P fuse junction panel or individual connector. Mini ISO Relay Using Digital Multimeter, check for the continuity between terminal 85 and all other terminals. If the resistance is 5 ohms or less between terminal 85 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay terminals 86 and 30 directly to the positive battery terminal. Use Digital Multimeter set in the volts position to check for voltage at terminal 87A. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 85 and ground the jumper wire to a known good ground. Check for voltage at terminal 87. If battery voltage is not indicated, replace the relay. Micro ISO Relay Use Digital Multimeter to check for the continuity between terminal 2 and all other terminals. If resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay terminals 1 and 3 directly to the positive battery terminal. Use Digital Multimeter set in the volts position to check for voltage at terminal 4. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 2 and ground the jumper wire to a known good ground. Check for voltage at terminal 5. If battery voltage is not indicated, replace the relay. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay Windshield Washer Relay: Locations Front Washer Pump Relay Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay > Page 381 Power Distribution Box The Front Washer Pump Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay > Page 382 Windshield Washer Relay: Locations Rear Washer Pump Relay Power Distribution Relay Box The Rear Washer Pump Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay Wiper Relay: Locations Wiper High/Low Relay Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 387 Power Distribution Box The Wiper High-Low Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 388 Wiper Relay: Locations Wiper Run/Park Relay Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 389 Power Distribution Box The Wiper Run/Park Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Service and Repair Lock Cylinder Switch: Service and Repair REMOVAL NOTE: In the images, the steering wheel is removed for clarity. 1. If equipped, twist the tilt wheel handle and shank and remove. 2. Remove the lower steering column shroud. 1. Remove the three lower steering column shroud screws. 2. Remove the lower steering column shroud. 3. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to RUN position. 2. Push the (A) ignition switch lock cylinder release tab with a punch while pulling out the (B) ignition switch lock cylinder. 4. Carefully pry to release the four clips and remove the steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Service and Repair > Page 395 5. Remove the upper steering column shroud. 6. Remove the upper instrument panel steering column cover. 7. Remove the ignition lock anti-theft switch. 1. Disconnect the electrical connector. 2. Remove the ignition lock anti-theft switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Left Door Left Power Door Lock Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Left Door > Page 401 Right Power Door Lock Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams Power Mirror Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Customer Interest for Power Seat Switch: > 98-20-19 > Oct > 98 > Power Seat Switch - Button Comes Off Power Seat Switch: Customer Interest Power Seat Switch - Button Comes Off Article No. 98-20-19 10/12/98 POWER SEAT SWITCH - BUTTON COMES OFF LIGHT TRUCK: 1995-99 EXPLORER 1997-99 ECONOLINE, EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE The power seat control button (knob) may detach from the switch actuator. This may be due to insufficient adhesion between the button and the switch actuator. ACTION Attach a new button and use an adhesive to reduce the possibility of the button detaching from the actuator. The button was not previously adhered. This revised process has been tested for shear and pull strengths. Refer to the following text for details. Refer to the Instruction Sheet included with Knob Kit (F85Z-14711-AA). Ford Instant Adhesive (E8AZ-19554-A) or equivalent meeting Ford specification WSK-M2G402-A4 is not included with the kit, but is required to complete this repair procedure. Order Ford Instant Adhesive separately. PART NUMBER PART NAME F85Z-14711-AA Knob Kit E8AZ-l9554-A Instant Adhesive OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982019A Install Power Seat Control 0.2 Hr. Button DEALER CODING CONDITION BASIC PART NO. CODE 14711 68 OASIS CODES: 101000, 107000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Seat Switch: > 98-20-19 > Oct > 98 > Power Seat Switch - Button Comes Off Power Seat Switch: All Technical Service Bulletins Power Seat Switch - Button Comes Off Article No. 98-20-19 10/12/98 POWER SEAT SWITCH - BUTTON COMES OFF LIGHT TRUCK: 1995-99 EXPLORER 1997-99 ECONOLINE, EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE The power seat control button (knob) may detach from the switch actuator. This may be due to insufficient adhesion between the button and the switch actuator. ACTION Attach a new button and use an adhesive to reduce the possibility of the button detaching from the actuator. The button was not previously adhered. This revised process has been tested for shear and pull strengths. Refer to the following text for details. Refer to the Instruction Sheet included with Knob Kit (F85Z-14711-AA). Ford Instant Adhesive (E8AZ-19554-A) or equivalent meeting Ford specification WSK-M2G402-A4 is not included with the kit, but is required to complete this repair procedure. Order Ford Instant Adhesive separately. PART NUMBER PART NAME F85Z-14711-AA Knob Kit E8AZ-l9554-A Instant Adhesive OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982019A Install Power Seat Control 0.2 Hr. Button DEALER CODING CONDITION BASIC PART NO. CODE 14711 68 OASIS CODES: 101000, 107000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 418 Power Seat Switch: Specifications Seat Regulator Control Switch Screws ................................................................................................................................................... 1-3 Nm (9-26 in lb) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 419 Power Seat Control Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 420 Power Seat Switch: Testing and Inspection Left Front Seat Control Switch Left Front Seat Control Switch - Component Testing Procedure (Part 1 Of 2) Left Front Seat Control Switch - Component Testing Procedure (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 421 Left Front Seat Control Switch - Terminal Locations Left Front Seat Control Switch - Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 422 Power Seat Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front seat back adjust handle. 1. Remove the screw. 2. Remove the front seat back adjust handle. 3. Pull to remove the front seat lumbar support handle. 4. Remove the front seat track shield screws. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 423 5. Remove the pushpin on the back of the front seat track shield. 6. Remove the screws on the bottom of the front seat track shield. 7. Disconnect the seat regulator control switch from the front of the front seat track shield. 1. Remove the screws. 2. Disconnect the seat regulator control switch. 8. Disconnect the seat regulator control switch electrical connector and remove the seat regulator control switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 424 INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams Moonroof Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Page 432 Brake Fluid Level Sensor/Switch: Description and Operation FLOAT AND MAGNET The brake fluid level warning switch is an integral part of the brake master cylinder reservoir. It consists of a float containing a magnet and a reed switch mounted in the bottom of the brake master cylinder reservoir. PURPOSE When the brake fluid in the brake master cylinder reservoir gets to a predetermined level, the floating magnet actuates the reed switch, causing the red brake warning indicator to illuminate. Loss of brake fluid from either the primary (front) or secondary (rear) system will cause this system to activate. If the brake fluid level warning switch is inoperative, the brake master cylinder reservoir must be replaced. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Service and Repair Braking Sensor/Switch: Service and Repair REMOVAL Disconnect the brake pedal to power brake booster push rod. 1. Remove the self-locking pin. 2. Remove the brake on/off (BOO) switch. 3. Separate the (A) BOO switch from the (B) brake master cylinder push rod. 4. Remove the brake master cylinder push rod spacer. 5. Remove the brake master cylinder push rod bushing. INSTALLATION To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Anti-Lock Brake Sensor Screws 63-80 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Differential Speed Sensor Wheel Speed Sensor: Locations Differential Speed Sensor Body View The Differential Speed Sensor is located on rear axle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Differential Speed Sensor > Page 441 Wheel Speed Sensor: Locations Wheel Speed Sensor Left Front Engine View The Left Front Wheel 4 Wheel Anti-Lock Brake System Sensor is located at the left front wheel. Right Front Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Differential Speed Sensor > Page 442 Engine View The Right Front Wheel 4 Wheel Anti-Lock Brake System Sensor is located at the Right front wheel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring Wheel Speed Sensor: Service and Repair Toothed Ring Rear The differential case must be disassembled and assembled to replace the rear sensor indicator. Refer to Transmission and Drivetrain for details. Removal and Installation The front brake anti-lock sensor indicator is integral to the front wheel hub. Refer to Transmission and Drivetrain for details. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 445 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Front REMOVAL 1. Disconnect the front brake anti-lock sensor electrical connector. 2. Remove the front disc brake rotor shield. 3. Remove the (A) two front brake anti-lock sensor bolts and the (B) front brake anti-lock sensor. INSTALLATION 1. To install, reverse the removal procedure. Rear REMOVAL Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 446 Remove the rear brake anti-lock sensor. 1. Disconnect the electrical connector. 2. Remove the bolt. 3. Remove the rear brake anti-lock sensor. NOTE: Remove all dirt from mounting surface and sensor to prevent contamination of rear axle lubrication. INSTALLATION Clean and inspect the rear brake anti-lock sensor. 1. Clean the axle mounting surface. Use care not to get dirt in the rear axle housing. 2. Inspect and clean the magnetized rear brake anti-lock sensor pole piece. 3. Inspect the rear anti-lock brake control o-ring for damage. Replace if necessary. 4. Lightly lubricate the rear anti-lock brake control o-ring with engine oil. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 447 Rear Brake And Anti-Lock Sensor Install the rear brake anti-lock sensor. 1. Position the rear brake anti-lock sensor and install the rear brake anti-lock sensor bolt. NOTE: Do not apply force to the plastic rear brake anti-lock sensor connector. 2. Connect the electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Coolant Temperature Sensor Coolant Temperature Sensor/Switch (For Computer): Locations Coolant Temperature Sensor Engine View The Engine Coolant Temperature Sensor is located in front of the engine. NOTE: In some applications of the 4.6L engine, the Cylinder Head Temperature (CHT) sensor provides the signal used by the Powertrain Control Module (PCM) in place of the Coolant Temperature Sensor (CTS) for functions such as, but not limited to, activating the electric cooling fans. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Coolant Temperature Sensor > Page 454 Engine Views Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 455 Coolant Temperature Sensor/Switch (For Computer): Description and Operation The Engine Coolant Temperature (ECT) sensor: - Sends the PCM a signal indicating engine temperature. - Resistance decreases as coolant temperature increases. NOTE: In some applications of the 4.6L engine, the Cylinder Head Temperature (CHT) sensor provides the signal used by the Powertrain Control Module (PCM) in place of the Coolant Temperature Sensor (CTS) for functions such as, but not limited to, activating the electric cooling fans. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 456 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Partially drain the cooling system. 3. Remove the Engine Coolant Temperature (ECT) sensor . 1 Disconnect the electrical connector. 2 Remove the ECT sensor. INSTALLATION 1. Install the ECT. 2. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications Radiator Cooling Fan Temperature Sensor / Switch: Specifications Switch Torque Switch Torque Cooling Fan Switch 8-18 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications > Page 460 Radiator Cooling Fan Temperature Sensor / Switch: Locations Engine View The Engine Coolant Temperature Sensor is located in front of the engine. NOTE: In some applications of the 4.6L engine, the Cylinder Head Temperature (CHT) sensor provides the signal used by the Powertrain Control Module (PCM) in place of the Coolant Temperature Sensor (CTS) for functions such as, but not limited to, activating the electric cooling fans. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications > Page 461 Radiator Cooling Fan Temperature Sensor / Switch: Description and Operation NOTE: In some applications of the 4.6L engine, the Cylinder Head Temperature (CHT) sensor provides the signal used by the Powertrain Control Module (PCM) in place of the Coolant Temperature Sensor (CTS) for functions such as, but not limited to, activating the electric cooling fans. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications Engine Temperature Sensor: Specifications Cylinder Head Temperature (CHT) Sensor 25 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications > Page 465 Engine Temperature Sensor: Locations Engine View The Cylinder Head Temperature Sensor is located at top front of the engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications > Page 466 Engine Temperature Sensor: Description and Operation FEATURES The Cylinder Head Temperature (CHT) sensor: - Is mounted into the wall of the cylinder head and is not connected to any coolant passages. Sends a signal to the PCM indicating the cylinder head temperature. - If the temperature exceeds: 130°C (265°F) the PCM disables four fuel injectors at a time. The PCM will alternate which four injectors are disabled every 32 engine cycles. The four cylinders that are not being fuel injected act as air pumps to aid in cooling the engine. - If the temperature exceeds: 166°C (330°F) the PCM disables all of the fuel injectors until the engine temperature drops below: 153°C (308°F) - If the engine reaches critical temperature, the following happens: - The coolant temperature gauge pointer will read fully hot at 121°C (250°F). - The check gauge warning indicator will illuminate. - DTCs are set. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications > Page 467 Engine Temperature Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the Cylinder Head Temperature (CHT) sensor. 1 Disconnect the electrical connector. 2 Remove the CHT sensor. INSTALLATION 1. Install the CHT. 2. Install the intake manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications Temperature Sensor (Gauge): Specifications TORQUE SPECIFICATIONS Water Temperature Indicator Sending Unit ......................................................................................................................... 16-24 Nm (11.7-17.6 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications > Page 471 Temperature Sensor (Gauge): Description and Operation The water temperature indicator sender unit: - Provides a gauge signal for coolant temperature. - Is mounted on the top front of the upper intake manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications > Page 472 Temperature Sensor (Gauge): Service and Repair REMOVAL 1. Partially drain the cooling system. 2. Remove the water temperature indicator sender unit. a. Disconnect the electrical connector. b. Remove the water temperature indicator sender unit. INSTALLATION 1. Install the water temperature indicator sender unit. a. Install the water temperature indicator sender unit. b. Connect the electrical connector. 2. Fill the cooling system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 482 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 483 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 484 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 485 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 486 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 487 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 488 Attachment III - Technical Information Table of Contents Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 489 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 490 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 491 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 492 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 493 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 494 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 495 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 496 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 497 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 498 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 499 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 500 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 501 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 502 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 503 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 504 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 505 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 506 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 507 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): Recalls Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 512 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Brake Switch (Cruise Control): Recalls Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 522 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 523 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 524 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 525 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 526 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 527 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 528 Attachment III - Technical Information Table of Contents Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 529 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 530 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 531 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 532 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 533 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 534 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 535 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 536 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 537 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 538 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 539 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 540 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 541 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 542 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 543 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 544 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 545 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 546 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 547 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): All Technical Service Bulletins Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 552 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Brake Switch (Cruise Control): All Technical Service Bulletins Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 557 Brake Switch (Cruise Control): Specifications Brake Pressure Switch ........................................................................................................................ ................................................ 15-20 Nm 11-14 Lb Ft Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 558 Brake Switch (Cruise Control): Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the brake pressure switch electrical connector. 3. Remove the brake pressure switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive systems may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. NOTE: After the procedure is finished refer to brake bleeding procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Recalls for Cruise Control Switch: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Cruise Control Switch: Recalls Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Cruise Control Switch: All Technical Service Bulletins Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 572 Cruise Control Switch: Service and Repair REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REMOVING AN AIR BAG. - CARRY A LIVE AIR BAG WITH THE BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. AN ACCIDENTAL DEPLOYMENT WILL THEN DEPLOY WITH A MINIMAL CHANCE OF INJURY. - PLACE A LIVE AIR BAG ON A BENCH OR OTHER SURFACE WITH THE TRIM COVER UP. - NEVER PROBE THE CONNECTORS ON THE AIR BAGS. DOING SO MAY RESULT IN AIR BAG DEPLOYMENT WHICH COULD RESULT IN PERSONAL INJURY. - TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REMOVING OR REPLACING ANY AIR BAG SYSTEM COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY TO STARTER CABLE AND WAIT ONE MINUTE. 1. Disconnect the battery cables. 1. Disconnect the battery ground cable. 2. Disconnect the battery to starter relay cable and wait one minute for the backup power supply to be depleted. 2. Remove the driver side air bag module. 1. Remove two air bag module screws. 2. Disconnect the air bag sliding contact electrical connector. 3. Disconnect the horn electrical connector. 4. Remove the driver side air bag module. WARNING: PLACE AIR BAG MODULE ON BENCH WITH TRIM COVER FACING UP. 3. Remove the speed control actuator switch. 1. Release the four (A) speed control actuator switch clips and (B) remove the speed control actuator switch 2. Disconnect the speed control actuator switch electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 573 INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Specifications Oil Pressure Switch (For Fuel Pump): Specifications Oil Pressure Switch 12-16 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Specifications > Page 578 Oil Pressure Switch (For Fuel Pump): Testing and Inspection To avoid potential misdiagnosis and the unnecessary replacement of components, it is recommended that diagnosis and testing begin with Diagnostic Routines (Diagnosis by Symptom) at the Powertrain Management level. The Diagnostic Routines will lead the technician through the logical and methodical testing of a "specific" subsystem and it's related wiring and components. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Specifications > Page 579 Oil Pressure Switch (For Fuel Pump): Service and Repair REMOVAL 1. Disconnect the oil pressure switch electrical connector. 2. Remove the oil pressure switch from the oil filter adapter. INSTALLATION 1. To install, reverse the removal procedure. 2. Check the oil level and fill to specification with Ford Premium SAE 1OW-30 Motor Oil XO-1OW-30-BSP, DSP, QSP or equivalent meeting Ford specification ESE-M2C153-E. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Door Position Sensor / Switch, HVAC > Component Information > Diagrams > Air Door Position Sensor / Switch, HVAC Air Door Position Sensor / Switch: Diagrams Air Door Position Sensor / Switch, HVAC Front Mode Potentiometer Rear Mode Potentiometer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Door Position Sensor / Switch, HVAC > Component Information > Diagrams > Air Door Position Sensor / Switch, HVAC > Page 585 Air Door Position Sensor / Switch: Diagrams Blend Door Position Sensor Front Blend Potentiometer Rear Blend Potentiometer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Blower Switch Blower Motor Switch: Diagrams Blower Switch Front Blower Motor Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Blower Switch > Page 590 Rear Blower Motor Switch Rear Integrated Control Panel (Rear Blower Switch) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Blower Switch > Page 591 Blower Motor Switch: Diagrams Blower Switch Illumination Front Blower Switch Illumination Rear Blower Switch Illumination Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Testing and Inspection > Blower Switch Blower Motor Switch: Testing and Inspection Blower Switch Blower Motor Switch - Component Testing Procedure Blower Motor Switch - Terminal Locations Blower Motor Switch - Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Testing and Inspection > Blower Switch > Page 594 Blower Motor Switch: Testing and Inspection Front Blower Switch Front Blower Motor Switch - Component Testing Procedure Front Blower Motor Switch - Terminal Locations Front Blower Motor Switch - Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Testing and Inspection > Blower Switch > Page 595 Blower Motor Switch: Testing and Inspection Rear Auxiliary Rear Blower Motor Switch - Component Testing Procedure Rear Blower Motor Switch - Terminal Locations Rear Blower Motor Switch - Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications Refrigerant Pressure Sensor / Switch: Specifications Pressure Cut-Off Switch ............................................................................................................................................................ 6.8-1.3 N.m (61-121 Lb/In) A/C Cycling Switch ................................................................................... .................................................................................. 1.4-5.4 N.m (12-48 Lb/In) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Cutoff Switch Typical Air Conditioning Pressure Sensor An A/C pressure cut off switch is used on all vehicles to interrupt operation of the A/C compressor in the event of high system discharge pressures. The switch is located in the discharge line between the A/C compressor and the A/C condenser core. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch > Page 601 Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Switch The A/C cycling switch is mounted on a Schrader-type fitting on the top of the suction accumulator/drier. A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the Schrader valve stem. This allows the suction pressure inside the suction accumulator/drier to control the operation of the A/C cycling switch. The electrical switch contacts open when the suction pressure drops to 151-165 kPa (22.0-24.0 psi). The contacts close when the suction pressure rises to 276-324 kPa (40-47 psi). This is due to the pressure/temperature relationship of the refrigerant and the requirement of the system pressure to reach 276-324 kPa (40-47 psi) to close the A/C cycling pressure switch contacts. These contacts control the electrical circuit to the A/C clutch field coil. When the A/C cycling pressure switch contacts close, voltage is supplied to energize the A/C clutch for operation of the A/C compressor. When the A/C cycling pressure switch contacts open, the A/C clutch is de-energized and operation of the A/C compressor stops. The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin surface temperature will be maintained slightly above freezing. This prevents icing of the A/C evaporator core and blockage of airflow. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch Refrigerant Pressure Sensor / Switch: Service and Repair A/C Cycling Switch REMOVAL 1. Disconnect the A/C cycling pressure switch electrical connector. 2. Remove the A/C cycling switch from the top of the suction accumulator/drier. INSTALLATION 1. Lubricate the new O-ring seal. ^ Use Motorcraft YN-12b Refrigerant Oil F2AZ-19577-AC or equivalent meeting Ford specification WSH-M1C231-B. 2. Install the A/C cycling switch onto the top of the suction accumulator/drier. 3. Reconnect the A/C cycling pressure switch wiring connector. 4. Check for refrigerant leaks. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch > Page 604 Refrigerant Pressure Sensor / Switch: Service and Repair A/C Pressure Cut-Off Switch REMOVAL 1. Disconnect the A/C pressure cut-off switch electrical connector or discharge line. 2. Remove the A/C pressure cut-off switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Description and Operation Dimmer Switch: Description and Operation The panel dimmer switch is integrated into the headlamp switch and controls the interior lamps by activating the interior lamp relay. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Directional Sensor > Component Information > Locations Directional Sensor: Locations Body View The Compass Sensor is located in the overhead console. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Directional Sensor > Component Information > Locations > Page 612 Compass Sensor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly Technical Service Bulletin # 97B17 Date: 980201 Campaign - Fuel Gauge/Sender Assembly 97517 OWNER NOTIFICATION PROGRAM Fuel Gauge/Sender Assembly Replacement Original - February, 1998 Dealer Letter Attachment I ^ Administrative Information ^ Refund Codes Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Supplement # 1 - April, 1998 Supplement # 2 - November, 1998 Revised Expiration Date For Owner Notification Program 98B17 - Fuel Gauge/sender Replacement ^ IMPORTANT INFORMATION OWNER NOTIFICATION PROGRAM 97B17 EXPIRATION DATE ^ Attachments not Applicable ^ Customer Notification Letter not Applicable Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 621 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Affected vehicles on the enclosed list. ^ Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 622 Enter claims using DWE. See ACESII Manual, Sections 5 and 6. OWNER REFUNDS See ACESII Manual, Section 3-63 for submission procedures. For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Program Code - 97B17 Misc. Expense - REFUND Misc. Expense - ADMIN. Misc. Expense - 0.2 Hr. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order fuel sender assemblies and the gaskets through normal processing channels. PART NUMBER/DESCRIPTION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 623 Fuel Sender Assembly - NOTE: Some of the following applications will require gaskets to be ordered in addition to the sender assemblies. DEALER PRICE For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. CLAIMS PREPARATION Enter using DWE. Use code information shown below: ^ Program Code - 97B17 ^ Labor Operation Code - See Above See Sections 5 and 6 of the ACESII Manual for detailed instructions Affected Vehicle and Warning Information AFFECTED VEHICLES: CERTAIN 1997 TAURUS/SABLE, EXPLORER/MOUNTAINEER, EXPEDITION, MUSTANG AND 1998 WINDSTAR WARNING DO NOT SWALLOW GASOLINE, THESE FUELS ARE HIGHLY TOXIC AND IF SWALLOWED CAN CAUSE DEATH OR PERMANENT INJURY, SWALLOWING METHANOL CAN ALSO CAUSE BLINDNESS. CALL A PHYSICIAN IMMEDIATELY TO TREAT ANYONE WHO HAS SWALLOWED FUEL METHANOL OR FUEL ETHANOL. VOMITING SHOULD BE INDUCED BY OR UNDER THE DIRECTION OF A PHYSICIAN OR POISON CONTROL CENTER. BE AWARE THAT THE ONSET OF POTENTIAL ILL HEALTH EFFECTS MAY BE DELAYED. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 624 WARNING AVOID INHALING FUEL VAPORS. INHALING TOO MUCH FUEL VAPOR CAN LEAD TO EYE AND RESPIRATORY TRACT IRRITATION. IN SEVERE CASES, EXCESSIVE OR PROLONGED BREATHING OF FUEL VAPORS CAN CAUSE SERIOUS ILLNESS AND PERMANENT INJURY SUCH AS BLINDNESS. WARNING AVOID GETTING GASOLINE IN YOUR EYES. IF YOU GET ANY FUEL IN YOUR EYES, REMOVE CONTRACT LENSES (IF WORN), FLUSH IMMEDIATELY WITH PLENTY OF WATER FOR AT LEAST 15 MINUTES AND SEEK MEDICAL ATTENTION. WARNING IF YOU GET ANY FUEL ON YOUR SKIN, WASH WITH SOAP AND WATER. REPEATED OR PROLONGED SKIN CONTACT WITH FUEL LIQUID OR VAPOR CAUSES SKIN IRRITATION. WARNING DO NOT OPERATE ENGINE OR SMOKE WHILE REFUELING. Expedition 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Raise and support vehicle. 4. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 5. Disconnect fuel filler and vent hoses from fuel tank. Refer to Figure 1. 6. Disconnect rear EVAP hose from top of fuel tank. See Figure 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 625 7. Support fuel tank with adjustable jack. 8. Remove fuel tank straps retaining bolts. The skid plate, fuel tank and straps will be removed as an assembly. 9. Slightly lower fuel tank. 10. Disconnect fuel supply and return lines from top of fuel tank. See Figure 2. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 626 11. Disconnect fuel pump electrical connector, located between the side of the fuel tank and the frame rail. See Figure 3. 12. Slightly lower fuel tank again. 13. Disconnect front EVAP hose from top of fuel tank. 14. Remove fuel tank from vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 627 15. Clean area around fuel pump to prevent foreign material from entering fuel tank. Refer to Figure 4. 16. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel pump during reassembly. 17. Remove fuel pump lock-ring, then remove fuel pump. See Figure 4. 18. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 628 19. Disconnect fuel sender electrical connectors. Refer to Figure 5. 20. Remove fuel sender retaining screws, then remove fuel sender. See Figure 5. 21. Install new fuel sender on fuel pump. Tighten screws to 2 Nm (18 lb/in). 22. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 23. Clean fuel pump-to-gas tank mating surface. 24. Install new seal onto fuel pump-to-gas tank mating surface. 25. Install fuel pump. Align marks made during disassembly. Tighten lock-ring to 44 Nm (33 lb/ft). 26. Position fuel tank under vehicle. 27. Raise fuel tank enough to connect front EVAP hose. 28. Connect front EVAP hose. 29. Raise fuel tank enough to connect fuel lines. 30. Connect fuel supply and return lines. 31. Connect fuel pump electrical connector. 32. Raise fuel tank to installed position. 33. Install fuel tank strap retaining bolts. Tighten bolts to 46-63 Nm (33-46 lb/ft). 34. Remove jack. 35. Connect rear EVAP hose to top of fuel tank. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 629 36. Connect fuel filler and vent hoses to fuel tank. 37. Refill fuel tank. It may be necessary to refill fuel tank before connecting filler hose. 38. Lower vehicle. 39. Connect battery negative cable, then remove memory saver. 40. Stan and run engine. 41. Raise vehicle. 42. Inspect fuel system for leaks. 43. Lower vehicle. Explorer/Mountaineer 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Raise and support vehicle. 4. Remove skid plate retaining bolts, then the skid plate. 5. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 6. Support fuel tank with adjustable jack. 7. Disconnect fuel filler and vent hoses from fuel tank. 8. Remove fuel tank strap retaining bolt. 9. Remove fuel tank-to-front support bracket retaining bolts. 10. Slightly lower fuel tank. Push fuel tank back until lip of tank clears support bracket. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 630 11. Disconnect fuel supply, return and vapor lines from top of fuel tank. See Figure 6. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 631 12. Disconnect fuel pump electrical connector, located in frame rail. See Figure 7. 13. Remove fuel tank from vehicle. 14. Disconnect fuel tank pressure transducer electrical connector. Refer to Figure 8. 15. Clean area around fuel pump to prevent foreign material from entering fuel tank. 16. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel pump during assembly. 17. Remove fuel pump retaining screws, then remove fuel pump. See Figure 8. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 632 18. Disconnect fuel sender electrical connectors. Refer to Figure 9. 19. Remove fuel sender retaining screws, then remove fuel sender. See Figure 9. 20. Install new fuel sender on fuel pump. Tighten screws to 2 Nm (18 lb/in). 21. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 22. Clean fuel pump-to-gas tank mating surface. 23. Install fuel pump. Align marks made during disassembly. Tighten retaining screws to 9-12 Nm (80-107 lb/in). 24. Connect fuel tank pressure transducer electrical connector. 25. Position fuel tank under vehicle. 26. Raise fuel tank enough to connect fuel lines. 27. Connect fuel supply and return lines. 28. Connect fuel pump electrical connector. 29. Position fuel tank in installed position. 30. Install fuel tank-to-front support bracket retaining bolts. Tighten bolts to 34-46 Nm (25-34 lb/ft). 31. Install fuel tank strap retaining bolt. Tighten bolts to 34-46 Nm (25-34 lb/ft). 32. Remove jack. 33. Connect fuel filler and vent hoses to fuel tank. 34. Install skid plate. Torque retaining bolts to 34-46 Nm (25-34 lb/ft). 35. Lower vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 633 36. Fill fuel tank. 37. Connect battery negative cable, then remove memory saver. 38. Start and run engine. 39. Raise vehicle. 40. Inspect fuel system for leaks. 41. Lower vehicle. Mustang 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 4. Remove fuel filler pipe retainers from gas cap side of fuel filler pipe. 5. Raise and support vehicle. 6. Remove screw retaining fuel filler pipe retainer to fuel tank flange.Refer to Figure 10. 7. Remove fuel filler pipe rubber weather boot from inner fender well. See Figure 10. 8. Support fuel tank with adjustable jack. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 634 9. Disconnect fuel pump electrical connector. See Figure 11. 10. Remove fuel tank straps retaining bolts. 11. Slightly lower fuel tank. 12. With an assistant's help, remove filler pipe from fuel tank. The filler pipe is friction fit into the fuel tank, the filler pipe will have to be walked out of the fuel tank. See Figure 12. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 635 13. Disconnect fuel supply, return and vapor lines. See Figure 13. 14. Disconnect fuel sender electrical connector. Refer to Figure 14. 15. Remove fuel tank from vehicle. 16. Clean area around fuel sender to prevent foreign material from entering fuel tank. 17. Place alignment mark across fuel sender and fuel tank. This will assure correct alignment of fuel sender during assembly. 18. Remove fuel sender lock-ring. See Figure 14. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 636 19. Remove and discard fuel sender. 20. Remove and discard fuel sender seal. 21. Lubricate and install new fuel sender seal. 22. Install new fuel sender. Align mark made during disassembly. Tighten lock ring until it contact stops. 23. Connect fuel sender electrical connector. 24. Raise fuel tank enough to connect fuel lines. 25. Connect fuel supply, return and vapor lines. 26. Install fuel filler pipe in fuel tank. 27. Position fuel tank in installed position. 28. Install fuel tank straps. Tighten retaining bolts to 30-40 Nm (22-30 lb/ft). 29. Remove adjustable jack. 30. Connect fuel pump electrical connector. 31. Install fuel filler pipe rubber weather boot to inner fender well. 32. Install screw retaining fuel filler pipe retainer to fuel tank flange. Tighten screw to 7.3-9.0 Nm (65-80 lb/in). 33. Lower vehicle. 34. Install fuel filler pipe retainers to gas cap side of fuel filler pipe. 35. Fill fuel tank. 36. Connect battery negative cable, then remove memory saver. 37. Start and run engine. 38. Raise vehicle. 39. Inspect fuel system for leaks. 40. Lower vehicle. Taurus/Sable 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 4. Raise and support vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 637 5. Disconnect fuel filler and vent hoses from fuel tank. See Figure 15. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 638 6. Disconnect fuel supply and return lines. Refer to Figure 16. 7. Disconnect fuel pump electrical connector. See Figure 16. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 639 8. Disconnect fuel vapor line. See Figure 17. 9. Support fuel tank with adjustable jack. 10. Remove fuel tank strap retaining bolts. 11. Remove fuel tank from vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 640 12. Detach fuel pump wiring harness and fuel lines from fuel tank. Refer to Figure 18. 13. Clean area around fuel pump to prevent foreign material from entering fuel tank. 14. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel pump during assembly. 15. Disconnect fuel pressure transducer electrical connector. See Figure 18. 16. Remove fuel pump lock-ring. 17. Remove fuel pump. 18. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 641 19. Disconnect fuel sender electrical connectors. Refer to Figure 19. 20. Remove fuel sender retaining screw, then remove fuel sender. See Figure 19. 21. Install new fuel sender on fuel pump. Tighten screw to 1 Nm (9 lb/in). 22. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 23. Clean fuel pump-to-gas tank mating surface. 24. Lubricate and install new fuel pump gasket. 25. Install fuel pump. Align marks made during disassembly. Tighten lock ring until it contacts stops. 26. Install fuel pump wiring harness and fuel lines on fuel tank assembly. 27. Connect fuel pressure transducer electrical connector. 28. Install fuel tank in vehicle. Tighten fuel tank straps to 30-40 Nm (22-30 lb/ft). 29. Remove adjustable jack. 30. Connect fuel pump electrical connector. 31. Connect fuel supply, return and vapor lines. 32. Connect fuel filler and vent hoses to fuel tank. 33. Lower vehicle. 34. Fill fuel tank. 35. Connect battery negative cable, then remove memory saver. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 642 36. Start and run engine. 37. Raise vehicle. 38. Inspect fuel system for leaks. 39. Lower vehicle. Windstar 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 4. Raise and support vehicle. 5. Support fuel tank with adjustable jack. 6. Disconnect fuel filler and vent hoses from fuel tank. 7. Disconnect fuel supply, return and vapor lines. See Figure 20. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 643 8. Disconnect fuel pump electrical connector. See Figure 21. 9. Remove fuel tank straps retaining bolts. 10. Remove fuel tank from vehicle. 11. Clean area around fuel pump to prevent foreign material from entering fuel tank. 12. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel during assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 644 13. Detach fuel lines from routing clips and tie strap. See Figure 22. 14. Remove fuel pump lock-ring. 15. Remove fuel pump. 16. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 645 17. Disconnect fuel sender electrical connectors. Refer to Figure 23. 18. Remove fuel sender retaining screw, then remove fuel sender. See Figure 23. 19. Install new fuel sender on fuel pump. Tighten screw to 1 Nm (9 lb/in). 20. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 21. Clean fuel pump-to-gas tank mating surface. 22. Install new fuel pump gasket. 23. Install fuel pump. Align marks made during disassembly. Tighten lock ring until it contact stops. 24. Attach fuel lines to routing clips and install tie strap. Connect fuel lines to fuel pump. Connect electrical connector to pump/sender. 25. Install fuel tank in vehicle. Tighten fuel tank straps to 41-54 Nm (31-39 lb/ft). 26. Connect fuel pump electrical connector. 27. Connect fuel supply, return and vapor lines. 28. Connect fuel filler and vent hoses to fuel tank. 29. Remove adjustable jack. 30. Lower vehicle. 31. Fill fuel tank. 32. Connect battery negative cable, then remove memory saver. 33. Start and run engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 646 34. Raise vehicle. 35. Inspect fuel system for leaks. 36. Lower vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 647 Supplement # 1 - Attachment II LABOR ALLOWANCES Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 648 PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order fuel sender assemblies and the gaskets through normal processing channels. PART NUMBER/DESCRIPTION Fuel Sender Assembly - NOTE: Some of the following applications will require gaskets to be ordered in addition to the sender assemblies. NOTE: Kit Codes "AA" & "BB" are not used. Warning For 1997 Expedition FUEL SENDER REPLACEMENT SUPPLEMENT FOR 1997 EXPEDITION WARNING DO NOT SWALLOW GASOLINE, THESE FUELS ARE HIGHLY TOXIC AND IF SWALLOWED CAN CAUSE DEATH OR PERMANENT INJURY, SWALLOWING METHANOL CAN ALSO CAUSE BLINDNESS. CALL A PHYSICIAN IMMEDIATELY TO TREAT ANYONE WHO HAS SWALLOWED FUEL METHANOL OR FUEL ETHANOL. VOMITING SHOULD BE INDUCED BY OR UNDER THE DIRECTION OF A PHYSICIAN OR POISON CONTROL CENTER. BE AWARE THAT THE ONSET OF POTENTIAL ILL HEALTH EFFECTS MAY BE DELAYED. WARNING AVOID INHALING FUEL VAPORS. INHALING TOO MUCH FUEL VAPOR CAN LEAD TO EYE AND RESPIRATORY TRACT IRRITATION. IN SEVERE CASES, EXCESSIVE OR PROLONGED BREATHING OF FUEL VAPORS CAN CAUSE SERIOUS ILLNESS AND PERMANENT INJURY SUCH AS BLINDNESS. WARNING AVOID GETTING GASOLINE IN YOUR EYES. IF YOU GET ANY FUEL IN YOUR EYES, REMOVE CONTACT LENSES (IF WORN), FLUSH IMMEDIATELY WITH PLENTY OF WATER FOR AT LEAST 15 MINUTES AND SEEK MEDICAL ATTENTION. WARNING IF YOU GET ANY FUEL ON YOUR SKIN, WASH WITH SOAP AND WATER. REPEATED OR PROLONGED SKIN CONTACT WITH FUEL LIQUID OR VAPOR CAUSES SKIN IRRITATION. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 649 WARNING DO NOT OPERATE ENGINE OR SMOKE WHILE REFUELING. Expedition 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Raise and support vehicle. 4. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 5. Disconnect fuel filler and vent hoses from fuel tank. Refer to Figure 1. 6. Disconnect rear EVAP hose from top of fuel tank. See Figure 1. 7. Support fuel tank with adjustable jack. 8. Remove fuel tank straps retaining bolts. The skid plate, fuel tank and straps will be removed as an assembly. 9. Slightly lower fuel tank. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 650 10. Disconnect fuel supply and return lines from top of fuel tank. See Figure 2. 11. Disconnect fuel pump electrical connector, located between the side of the fuel tank and the frame rail. See Figure 3. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 651 12. Slightly lower fuel tank again. 13. Disconnect front EVAP hose from top of fuel tank. 14. Remove fuel tank from vehicle. 15. Clean area around fuel pump to prevent foreign material from entering fuel tank. Refer to Figure 4. 16. Place alignment mark across fuel pump and fuel tank. This will correctly align the fuel pump during reassembly. 17. Remove fuel pump lock-ring, then remove fuel pump. See Figure 4. 18. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 652 19. Disconnect fuel sender electrical connectors. Refer to Figure 5. 20. Remove fuel sender retaining screws, then remove fuel sender. See Figure 5. NOTE: On some vehicles this step may have already been performed. CAUTION Do not cut the main 14 gauge pump ground wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 653 21. Cut a section out of the 18 gauge black grounding wire. See Figure 6. Discard removed black wire. 22. Install new fuel sender on the fuel pump. Tighten screws to 2 Nm (18 lb/in). Note the revised orientation of the float. NOTE: There are two (2) different terminal end types used on the fuel sender ground wire, a box terminal or a ring terminal. These terminal ends are connected to different locations on the fuel sender. 23. Connect fuel sender electrical connectors as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 654 ^ Connect box type terminal end ground wire to location shown in Figure 7. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 655 ^ Connect ring type terminal end ground wire to location shown in Figure 8. ^ Reconnect yellow wire to pump sending unit harness. 24. Clean fuel pump-to-gas tank mating surface. 25. Install new seal onto fuel pump-to-gas tank mating surface. 26. Install fuel pump. Align marks made during disassembly. Tighten lock-ring to 44 Nm (33 lb/ft). 27. Position fuel tank under vehicle. 28. Raise fuel tank enough to connect front EVAP hose. 29. Connect front EVAP hose. 30. Raise fuel tank enough to connect fuel lines. 31. Connect fuel supply and return lines. 32. Connect fuel pump electrical connector. 33. Raise fuel tank to installed position. 34. Install fuel tank strap retaining bolts. Tighten bolts to 46-63 Nm (33-46 lb/ft). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 656 35. Remove jack. 36. Connect rear EVAP hose to top of fuel tank. 37. Connect fuel filler and vent hoses to fuel tank. 38. Refill fuel tank. It may be necessary to refill fuel tank before connecting filler hose. 39. Lower vehicle. 40. Connect battery negative cable, then remove memory saver. 41. Stan and run engine. 42. Raise vehicle. 43. Inspect fuel system for leaks. 44. Lower vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest: > 97-9-16 > Apr > 97 > Fuel Gauge - Erratic and/or Inaccurate Readings Fuel Gauge Sender: Customer Interest Fuel Gauge - Erratic and/or Inaccurate Readings Article No. 97-9-16 04/28/97 GAUGES - FUEL - ERRATIC AND/OR INACCURATE READINGS - VEHICLES BUILT THROUGH 3/97 LIGHT TRUCK: 1997 EXPEDITION ISSUE: The fuel gauge may operate erratically and/or have inaccurate readings. This may be caused by the sensing float being positioned at the extreme aft of the fuel tank. ACTION: Replace the fuel pump and sender assembly with a revised pump and sender. The revised pump and sender has a repositioned sensor assembly to bring the float assembly closer to the center of the fuel tank. This should reduce the possibility of inaccurate and erratic readings. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the fuel tank as outlined in Section 310-01 in the 1997 Expedition Workshop Manual. 2. Remove the fuel pump and sender assembly as outlined in Section 310-01 of the Workshop Manual. NOTE: THERE IS NO NEED TO REMOVE THE SENDING UNIT FROM THE REMOVED PUMP. THE REPLACEMENT PUMP HAS A NEW SENDER FITTED ALREADY. THIS SENDER IS ORIENTED DIFFERENTLY FROM THE REMOVED PART. THIS WILL PUT THE FLOAT CLOSER TO THE CENTER OF THE TANK. 3. Remove the pressure transducer from the removed pump and install it onto the new pump. Make sure the electrical connection is made. 4. Using a new green seal (included with the pump), reinstall the pump and sender into the tank as outlined in Section 310-01 of the Workshop Manual. 5. Reinstall the fuel tank as outlined in Section 310-01 of the Workshop Manual. NOTE: WHEN THE BATTERY IS DISCONNECTED AND RECONNECTED, SOME ABNORMAL DRIVE SYMPTOMS MAY OCCUR WHILE THE VEHICLE RELEARNS ITS ADAPTIVE STRATEGY. THE VEHICLE MAY NEED TO BE DRIVEN 16 km (10 MILES) OR MORE TO RELEARN THE STRATEGY. PART NUMBER PART NAME F75Z-9H307-KC Fuel Pump And Sender Assembly (4X4) F75Z-9H307-LC Fuel Pump And Sender Assembly (4X2 Normal Suspension) F75Z-9H307-MC Fuel Pump And Sender Assembly (4X2 Air Suspension) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 970916A Replace Fuel Pump And 1.5 Hrs. Sender Assembly DEALER CODING CONDITION BASIC PART NO. CODE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest: > 97-9-16 > Apr > 97 > Fuel Gauge - Erratic and/or Inaccurate Readings > Page 662 9K007 36 OASIS CODES: 204000, 204200 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly Technical Service Bulletin # 97B17 Date: 980201 Campaign - Fuel Gauge/Sender Assembly 97517 OWNER NOTIFICATION PROGRAM Fuel Gauge/Sender Assembly Replacement Original - February, 1998 Dealer Letter Attachment I ^ Administrative Information ^ Refund Codes Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Supplement # 1 - April, 1998 Supplement # 2 - November, 1998 Revised Expiration Date For Owner Notification Program 98B17 - Fuel Gauge/sender Replacement ^ IMPORTANT INFORMATION OWNER NOTIFICATION PROGRAM 97B17 EXPIRATION DATE ^ Attachments not Applicable ^ Customer Notification Letter not Applicable Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 668 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Affected vehicles on the enclosed list. ^ Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 669 Enter claims using DWE. See ACESII Manual, Sections 5 and 6. OWNER REFUNDS See ACESII Manual, Section 3-63 for submission procedures. For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Program Code - 97B17 Misc. Expense - REFUND Misc. Expense - ADMIN. Misc. Expense - 0.2 Hr. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order fuel sender assemblies and the gaskets through normal processing channels. PART NUMBER/DESCRIPTION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 670 Fuel Sender Assembly - NOTE: Some of the following applications will require gaskets to be ordered in addition to the sender assemblies. DEALER PRICE For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. CLAIMS PREPARATION Enter using DWE. Use code information shown below: ^ Program Code - 97B17 ^ Labor Operation Code - See Above See Sections 5 and 6 of the ACESII Manual for detailed instructions Affected Vehicle and Warning Information AFFECTED VEHICLES: CERTAIN 1997 TAURUS/SABLE, EXPLORER/MOUNTAINEER, EXPEDITION, MUSTANG AND 1998 WINDSTAR WARNING DO NOT SWALLOW GASOLINE, THESE FUELS ARE HIGHLY TOXIC AND IF SWALLOWED CAN CAUSE DEATH OR PERMANENT INJURY, SWALLOWING METHANOL CAN ALSO CAUSE BLINDNESS. CALL A PHYSICIAN IMMEDIATELY TO TREAT ANYONE WHO HAS SWALLOWED FUEL METHANOL OR FUEL ETHANOL. VOMITING SHOULD BE INDUCED BY OR UNDER THE DIRECTION OF A PHYSICIAN OR POISON CONTROL CENTER. BE AWARE THAT THE ONSET OF POTENTIAL ILL HEALTH EFFECTS MAY BE DELAYED. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 671 WARNING AVOID INHALING FUEL VAPORS. INHALING TOO MUCH FUEL VAPOR CAN LEAD TO EYE AND RESPIRATORY TRACT IRRITATION. IN SEVERE CASES, EXCESSIVE OR PROLONGED BREATHING OF FUEL VAPORS CAN CAUSE SERIOUS ILLNESS AND PERMANENT INJURY SUCH AS BLINDNESS. WARNING AVOID GETTING GASOLINE IN YOUR EYES. IF YOU GET ANY FUEL IN YOUR EYES, REMOVE CONTRACT LENSES (IF WORN), FLUSH IMMEDIATELY WITH PLENTY OF WATER FOR AT LEAST 15 MINUTES AND SEEK MEDICAL ATTENTION. WARNING IF YOU GET ANY FUEL ON YOUR SKIN, WASH WITH SOAP AND WATER. REPEATED OR PROLONGED SKIN CONTACT WITH FUEL LIQUID OR VAPOR CAUSES SKIN IRRITATION. WARNING DO NOT OPERATE ENGINE OR SMOKE WHILE REFUELING. Expedition 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Raise and support vehicle. 4. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 5. Disconnect fuel filler and vent hoses from fuel tank. Refer to Figure 1. 6. Disconnect rear EVAP hose from top of fuel tank. See Figure 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 672 7. Support fuel tank with adjustable jack. 8. Remove fuel tank straps retaining bolts. The skid plate, fuel tank and straps will be removed as an assembly. 9. Slightly lower fuel tank. 10. Disconnect fuel supply and return lines from top of fuel tank. See Figure 2. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 673 11. Disconnect fuel pump electrical connector, located between the side of the fuel tank and the frame rail. See Figure 3. 12. Slightly lower fuel tank again. 13. Disconnect front EVAP hose from top of fuel tank. 14. Remove fuel tank from vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 674 15. Clean area around fuel pump to prevent foreign material from entering fuel tank. Refer to Figure 4. 16. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel pump during reassembly. 17. Remove fuel pump lock-ring, then remove fuel pump. See Figure 4. 18. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 675 19. Disconnect fuel sender electrical connectors. Refer to Figure 5. 20. Remove fuel sender retaining screws, then remove fuel sender. See Figure 5. 21. Install new fuel sender on fuel pump. Tighten screws to 2 Nm (18 lb/in). 22. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 23. Clean fuel pump-to-gas tank mating surface. 24. Install new seal onto fuel pump-to-gas tank mating surface. 25. Install fuel pump. Align marks made during disassembly. Tighten lock-ring to 44 Nm (33 lb/ft). 26. Position fuel tank under vehicle. 27. Raise fuel tank enough to connect front EVAP hose. 28. Connect front EVAP hose. 29. Raise fuel tank enough to connect fuel lines. 30. Connect fuel supply and return lines. 31. Connect fuel pump electrical connector. 32. Raise fuel tank to installed position. 33. Install fuel tank strap retaining bolts. Tighten bolts to 46-63 Nm (33-46 lb/ft). 34. Remove jack. 35. Connect rear EVAP hose to top of fuel tank. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 676 36. Connect fuel filler and vent hoses to fuel tank. 37. Refill fuel tank. It may be necessary to refill fuel tank before connecting filler hose. 38. Lower vehicle. 39. Connect battery negative cable, then remove memory saver. 40. Stan and run engine. 41. Raise vehicle. 42. Inspect fuel system for leaks. 43. Lower vehicle. Explorer/Mountaineer 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Raise and support vehicle. 4. Remove skid plate retaining bolts, then the skid plate. 5. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 6. Support fuel tank with adjustable jack. 7. Disconnect fuel filler and vent hoses from fuel tank. 8. Remove fuel tank strap retaining bolt. 9. Remove fuel tank-to-front support bracket retaining bolts. 10. Slightly lower fuel tank. Push fuel tank back until lip of tank clears support bracket. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 677 11. Disconnect fuel supply, return and vapor lines from top of fuel tank. See Figure 6. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 678 12. Disconnect fuel pump electrical connector, located in frame rail. See Figure 7. 13. Remove fuel tank from vehicle. 14. Disconnect fuel tank pressure transducer electrical connector. Refer to Figure 8. 15. Clean area around fuel pump to prevent foreign material from entering fuel tank. 16. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel pump during assembly. 17. Remove fuel pump retaining screws, then remove fuel pump. See Figure 8. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 679 18. Disconnect fuel sender electrical connectors. Refer to Figure 9. 19. Remove fuel sender retaining screws, then remove fuel sender. See Figure 9. 20. Install new fuel sender on fuel pump. Tighten screws to 2 Nm (18 lb/in). 21. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 22. Clean fuel pump-to-gas tank mating surface. 23. Install fuel pump. Align marks made during disassembly. Tighten retaining screws to 9-12 Nm (80-107 lb/in). 24. Connect fuel tank pressure transducer electrical connector. 25. Position fuel tank under vehicle. 26. Raise fuel tank enough to connect fuel lines. 27. Connect fuel supply and return lines. 28. Connect fuel pump electrical connector. 29. Position fuel tank in installed position. 30. Install fuel tank-to-front support bracket retaining bolts. Tighten bolts to 34-46 Nm (25-34 lb/ft). 31. Install fuel tank strap retaining bolt. Tighten bolts to 34-46 Nm (25-34 lb/ft). 32. Remove jack. 33. Connect fuel filler and vent hoses to fuel tank. 34. Install skid plate. Torque retaining bolts to 34-46 Nm (25-34 lb/ft). 35. Lower vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 680 36. Fill fuel tank. 37. Connect battery negative cable, then remove memory saver. 38. Start and run engine. 39. Raise vehicle. 40. Inspect fuel system for leaks. 41. Lower vehicle. Mustang 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 4. Remove fuel filler pipe retainers from gas cap side of fuel filler pipe. 5. Raise and support vehicle. 6. Remove screw retaining fuel filler pipe retainer to fuel tank flange.Refer to Figure 10. 7. Remove fuel filler pipe rubber weather boot from inner fender well. See Figure 10. 8. Support fuel tank with adjustable jack. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 681 9. Disconnect fuel pump electrical connector. See Figure 11. 10. Remove fuel tank straps retaining bolts. 11. Slightly lower fuel tank. 12. With an assistant's help, remove filler pipe from fuel tank. The filler pipe is friction fit into the fuel tank, the filler pipe will have to be walked out of the fuel tank. See Figure 12. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 682 13. Disconnect fuel supply, return and vapor lines. See Figure 13. 14. Disconnect fuel sender electrical connector. Refer to Figure 14. 15. Remove fuel tank from vehicle. 16. Clean area around fuel sender to prevent foreign material from entering fuel tank. 17. Place alignment mark across fuel sender and fuel tank. This will assure correct alignment of fuel sender during assembly. 18. Remove fuel sender lock-ring. See Figure 14. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 683 19. Remove and discard fuel sender. 20. Remove and discard fuel sender seal. 21. Lubricate and install new fuel sender seal. 22. Install new fuel sender. Align mark made during disassembly. Tighten lock ring until it contact stops. 23. Connect fuel sender electrical connector. 24. Raise fuel tank enough to connect fuel lines. 25. Connect fuel supply, return and vapor lines. 26. Install fuel filler pipe in fuel tank. 27. Position fuel tank in installed position. 28. Install fuel tank straps. Tighten retaining bolts to 30-40 Nm (22-30 lb/ft). 29. Remove adjustable jack. 30. Connect fuel pump electrical connector. 31. Install fuel filler pipe rubber weather boot to inner fender well. 32. Install screw retaining fuel filler pipe retainer to fuel tank flange. Tighten screw to 7.3-9.0 Nm (65-80 lb/in). 33. Lower vehicle. 34. Install fuel filler pipe retainers to gas cap side of fuel filler pipe. 35. Fill fuel tank. 36. Connect battery negative cable, then remove memory saver. 37. Start and run engine. 38. Raise vehicle. 39. Inspect fuel system for leaks. 40. Lower vehicle. Taurus/Sable 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 4. Raise and support vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 684 5. Disconnect fuel filler and vent hoses from fuel tank. See Figure 15. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 685 6. Disconnect fuel supply and return lines. Refer to Figure 16. 7. Disconnect fuel pump electrical connector. See Figure 16. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 686 8. Disconnect fuel vapor line. See Figure 17. 9. Support fuel tank with adjustable jack. 10. Remove fuel tank strap retaining bolts. 11. Remove fuel tank from vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 687 12. Detach fuel pump wiring harness and fuel lines from fuel tank. Refer to Figure 18. 13. Clean area around fuel pump to prevent foreign material from entering fuel tank. 14. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel pump during assembly. 15. Disconnect fuel pressure transducer electrical connector. See Figure 18. 16. Remove fuel pump lock-ring. 17. Remove fuel pump. 18. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 688 19. Disconnect fuel sender electrical connectors. Refer to Figure 19. 20. Remove fuel sender retaining screw, then remove fuel sender. See Figure 19. 21. Install new fuel sender on fuel pump. Tighten screw to 1 Nm (9 lb/in). 22. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 23. Clean fuel pump-to-gas tank mating surface. 24. Lubricate and install new fuel pump gasket. 25. Install fuel pump. Align marks made during disassembly. Tighten lock ring until it contacts stops. 26. Install fuel pump wiring harness and fuel lines on fuel tank assembly. 27. Connect fuel pressure transducer electrical connector. 28. Install fuel tank in vehicle. Tighten fuel tank straps to 30-40 Nm (22-30 lb/ft). 29. Remove adjustable jack. 30. Connect fuel pump electrical connector. 31. Connect fuel supply, return and vapor lines. 32. Connect fuel filler and vent hoses to fuel tank. 33. Lower vehicle. 34. Fill fuel tank. 35. Connect battery negative cable, then remove memory saver. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 689 36. Start and run engine. 37. Raise vehicle. 38. Inspect fuel system for leaks. 39. Lower vehicle. Windstar 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 4. Raise and support vehicle. 5. Support fuel tank with adjustable jack. 6. Disconnect fuel filler and vent hoses from fuel tank. 7. Disconnect fuel supply, return and vapor lines. See Figure 20. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 690 8. Disconnect fuel pump electrical connector. See Figure 21. 9. Remove fuel tank straps retaining bolts. 10. Remove fuel tank from vehicle. 11. Clean area around fuel pump to prevent foreign material from entering fuel tank. 12. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel during assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 691 13. Detach fuel lines from routing clips and tie strap. See Figure 22. 14. Remove fuel pump lock-ring. 15. Remove fuel pump. 16. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 692 17. Disconnect fuel sender electrical connectors. Refer to Figure 23. 18. Remove fuel sender retaining screw, then remove fuel sender. See Figure 23. 19. Install new fuel sender on fuel pump. Tighten screw to 1 Nm (9 lb/in). 20. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 21. Clean fuel pump-to-gas tank mating surface. 22. Install new fuel pump gasket. 23. Install fuel pump. Align marks made during disassembly. Tighten lock ring until it contact stops. 24. Attach fuel lines to routing clips and install tie strap. Connect fuel lines to fuel pump. Connect electrical connector to pump/sender. 25. Install fuel tank in vehicle. Tighten fuel tank straps to 41-54 Nm (31-39 lb/ft). 26. Connect fuel pump electrical connector. 27. Connect fuel supply, return and vapor lines. 28. Connect fuel filler and vent hoses to fuel tank. 29. Remove adjustable jack. 30. Lower vehicle. 31. Fill fuel tank. 32. Connect battery negative cable, then remove memory saver. 33. Start and run engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 693 34. Raise vehicle. 35. Inspect fuel system for leaks. 36. Lower vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 694 Supplement # 1 - Attachment II LABOR ALLOWANCES Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 695 PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order fuel sender assemblies and the gaskets through normal processing channels. PART NUMBER/DESCRIPTION Fuel Sender Assembly - NOTE: Some of the following applications will require gaskets to be ordered in addition to the sender assemblies. NOTE: Kit Codes "AA" & "BB" are not used. Warning For 1997 Expedition FUEL SENDER REPLACEMENT SUPPLEMENT FOR 1997 EXPEDITION WARNING DO NOT SWALLOW GASOLINE, THESE FUELS ARE HIGHLY TOXIC AND IF SWALLOWED CAN CAUSE DEATH OR PERMANENT INJURY, SWALLOWING METHANOL CAN ALSO CAUSE BLINDNESS. CALL A PHYSICIAN IMMEDIATELY TO TREAT ANYONE WHO HAS SWALLOWED FUEL METHANOL OR FUEL ETHANOL. VOMITING SHOULD BE INDUCED BY OR UNDER THE DIRECTION OF A PHYSICIAN OR POISON CONTROL CENTER. BE AWARE THAT THE ONSET OF POTENTIAL ILL HEALTH EFFECTS MAY BE DELAYED. WARNING AVOID INHALING FUEL VAPORS. INHALING TOO MUCH FUEL VAPOR CAN LEAD TO EYE AND RESPIRATORY TRACT IRRITATION. IN SEVERE CASES, EXCESSIVE OR PROLONGED BREATHING OF FUEL VAPORS CAN CAUSE SERIOUS ILLNESS AND PERMANENT INJURY SUCH AS BLINDNESS. WARNING AVOID GETTING GASOLINE IN YOUR EYES. IF YOU GET ANY FUEL IN YOUR EYES, REMOVE CONTACT LENSES (IF WORN), FLUSH IMMEDIATELY WITH PLENTY OF WATER FOR AT LEAST 15 MINUTES AND SEEK MEDICAL ATTENTION. WARNING IF YOU GET ANY FUEL ON YOUR SKIN, WASH WITH SOAP AND WATER. REPEATED OR PROLONGED SKIN CONTACT WITH FUEL LIQUID OR VAPOR CAUSES SKIN IRRITATION. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 696 WARNING DO NOT OPERATE ENGINE OR SMOKE WHILE REFUELING. Expedition 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Raise and support vehicle. 4. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 5. Disconnect fuel filler and vent hoses from fuel tank. Refer to Figure 1. 6. Disconnect rear EVAP hose from top of fuel tank. See Figure 1. 7. Support fuel tank with adjustable jack. 8. Remove fuel tank straps retaining bolts. The skid plate, fuel tank and straps will be removed as an assembly. 9. Slightly lower fuel tank. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 697 10. Disconnect fuel supply and return lines from top of fuel tank. See Figure 2. 11. Disconnect fuel pump electrical connector, located between the side of the fuel tank and the frame rail. See Figure 3. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 698 12. Slightly lower fuel tank again. 13. Disconnect front EVAP hose from top of fuel tank. 14. Remove fuel tank from vehicle. 15. Clean area around fuel pump to prevent foreign material from entering fuel tank. Refer to Figure 4. 16. Place alignment mark across fuel pump and fuel tank. This will correctly align the fuel pump during reassembly. 17. Remove fuel pump lock-ring, then remove fuel pump. See Figure 4. 18. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 699 19. Disconnect fuel sender electrical connectors. Refer to Figure 5. 20. Remove fuel sender retaining screws, then remove fuel sender. See Figure 5. NOTE: On some vehicles this step may have already been performed. CAUTION Do not cut the main 14 gauge pump ground wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 700 21. Cut a section out of the 18 gauge black grounding wire. See Figure 6. Discard removed black wire. 22. Install new fuel sender on the fuel pump. Tighten screws to 2 Nm (18 lb/in). Note the revised orientation of the float. NOTE: There are two (2) different terminal end types used on the fuel sender ground wire, a box terminal or a ring terminal. These terminal ends are connected to different locations on the fuel sender. 23. Connect fuel sender electrical connectors as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 701 ^ Connect box type terminal end ground wire to location shown in Figure 7. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 702 ^ Connect ring type terminal end ground wire to location shown in Figure 8. ^ Reconnect yellow wire to pump sending unit harness. 24. Clean fuel pump-to-gas tank mating surface. 25. Install new seal onto fuel pump-to-gas tank mating surface. 26. Install fuel pump. Align marks made during disassembly. Tighten lock-ring to 44 Nm (33 lb/ft). 27. Position fuel tank under vehicle. 28. Raise fuel tank enough to connect front EVAP hose. 29. Connect front EVAP hose. 30. Raise fuel tank enough to connect fuel lines. 31. Connect fuel supply and return lines. 32. Connect fuel pump electrical connector. 33. Raise fuel tank to installed position. 34. Install fuel tank strap retaining bolts. Tighten bolts to 46-63 Nm (33-46 lb/ft). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 703 35. Remove jack. 36. Connect rear EVAP hose to top of fuel tank. 37. Connect fuel filler and vent hoses to fuel tank. 38. Refill fuel tank. It may be necessary to refill fuel tank before connecting filler hose. 39. Lower vehicle. 40. Connect battery negative cable, then remove memory saver. 41. Stan and run engine. 42. Raise vehicle. 43. Inspect fuel system for leaks. 44. Lower vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97-9-16 > Apr > 97 > Fuel Gauge - Erratic and/or Inaccurate Readings Fuel Gauge Sender: All Technical Service Bulletins Fuel Gauge - Erratic and/or Inaccurate Readings Article No. 97-9-16 04/28/97 GAUGES - FUEL - ERRATIC AND/OR INACCURATE READINGS - VEHICLES BUILT THROUGH 3/97 LIGHT TRUCK: 1997 EXPEDITION ISSUE: The fuel gauge may operate erratically and/or have inaccurate readings. This may be caused by the sensing float being positioned at the extreme aft of the fuel tank. ACTION: Replace the fuel pump and sender assembly with a revised pump and sender. The revised pump and sender has a repositioned sensor assembly to bring the float assembly closer to the center of the fuel tank. This should reduce the possibility of inaccurate and erratic readings. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the fuel tank as outlined in Section 310-01 in the 1997 Expedition Workshop Manual. 2. Remove the fuel pump and sender assembly as outlined in Section 310-01 of the Workshop Manual. NOTE: THERE IS NO NEED TO REMOVE THE SENDING UNIT FROM THE REMOVED PUMP. THE REPLACEMENT PUMP HAS A NEW SENDER FITTED ALREADY. THIS SENDER IS ORIENTED DIFFERENTLY FROM THE REMOVED PART. THIS WILL PUT THE FLOAT CLOSER TO THE CENTER OF THE TANK. 3. Remove the pressure transducer from the removed pump and install it onto the new pump. Make sure the electrical connection is made. 4. Using a new green seal (included with the pump), reinstall the pump and sender into the tank as outlined in Section 310-01 of the Workshop Manual. 5. Reinstall the fuel tank as outlined in Section 310-01 of the Workshop Manual. NOTE: WHEN THE BATTERY IS DISCONNECTED AND RECONNECTED, SOME ABNORMAL DRIVE SYMPTOMS MAY OCCUR WHILE THE VEHICLE RELEARNS ITS ADAPTIVE STRATEGY. THE VEHICLE MAY NEED TO BE DRIVEN 16 km (10 MILES) OR MORE TO RELEARN THE STRATEGY. PART NUMBER PART NAME F75Z-9H307-KC Fuel Pump And Sender Assembly (4X4) F75Z-9H307-LC Fuel Pump And Sender Assembly (4X2 Normal Suspension) F75Z-9H307-MC Fuel Pump And Sender Assembly (4X2 Air Suspension) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 970916A Replace Fuel Pump And 1.5 Hrs. Sender Assembly DEALER CODING CONDITION BASIC PART NO. CODE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97-9-16 > Apr > 97 > Fuel Gauge - Erratic and/or Inaccurate Readings > Page 708 9K007 36 OASIS CODES: 204000, 204200 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97-9-16 > Apr > 97 > Fuel Gauge - Erratic and/or Inaccurate Readings Fuel Gauge Sender: All Technical Service Bulletins Fuel Gauge - Erratic and/or Inaccurate Readings Article No. 97-9-16 04/28/97 GAUGES - FUEL - ERRATIC AND/OR INACCURATE READINGS - VEHICLES BUILT THROUGH 3/97 LIGHT TRUCK: 1997 EXPEDITION ISSUE: The fuel gauge may operate erratically and/or have inaccurate readings. This may be caused by the sensing float being positioned at the extreme aft of the fuel tank. ACTION: Replace the fuel pump and sender assembly with a revised pump and sender. The revised pump and sender has a repositioned sensor assembly to bring the float assembly closer to the center of the fuel tank. This should reduce the possibility of inaccurate and erratic readings. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the fuel tank as outlined in Section 310-01 in the 1997 Expedition Workshop Manual. 2. Remove the fuel pump and sender assembly as outlined in Section 310-01 of the Workshop Manual. NOTE: THERE IS NO NEED TO REMOVE THE SENDING UNIT FROM THE REMOVED PUMP. THE REPLACEMENT PUMP HAS A NEW SENDER FITTED ALREADY. THIS SENDER IS ORIENTED DIFFERENTLY FROM THE REMOVED PART. THIS WILL PUT THE FLOAT CLOSER TO THE CENTER OF THE TANK. 3. Remove the pressure transducer from the removed pump and install it onto the new pump. Make sure the electrical connection is made. 4. Using a new green seal (included with the pump), reinstall the pump and sender into the tank as outlined in Section 310-01 of the Workshop Manual. 5. Reinstall the fuel tank as outlined in Section 310-01 of the Workshop Manual. NOTE: WHEN THE BATTERY IS DISCONNECTED AND RECONNECTED, SOME ABNORMAL DRIVE SYMPTOMS MAY OCCUR WHILE THE VEHICLE RELEARNS ITS ADAPTIVE STRATEGY. THE VEHICLE MAY NEED TO BE DRIVEN 16 km (10 MILES) OR MORE TO RELEARN THE STRATEGY. PART NUMBER PART NAME F75Z-9H307-KC Fuel Pump And Sender Assembly (4X4) F75Z-9H307-LC Fuel Pump And Sender Assembly (4X2 Normal Suspension) F75Z-9H307-MC Fuel Pump And Sender Assembly (4X2 Air Suspension) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 970916A Replace Fuel Pump And 1.5 Hrs. Sender Assembly DEALER CODING CONDITION BASIC PART NO. CODE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97-9-16 > Apr > 97 > Fuel Gauge - Erratic and/or Inaccurate Readings > Page 714 9K007 36 OASIS CODES: 204000, 204200 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly Technical Service Bulletin # 97B17 Date: 980201 Campaign - Fuel Gauge/Sender Assembly 97517 OWNER NOTIFICATION PROGRAM Fuel Gauge/Sender Assembly Replacement Original - February, 1998 Dealer Letter Attachment I ^ Administrative Information ^ Refund Codes Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Supplement # 1 - April, 1998 Supplement # 2 - November, 1998 Revised Expiration Date For Owner Notification Program 98B17 - Fuel Gauge/sender Replacement ^ IMPORTANT INFORMATION OWNER NOTIFICATION PROGRAM 97B17 EXPIRATION DATE ^ Attachments not Applicable ^ Customer Notification Letter not Applicable Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 720 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Affected vehicles on the enclosed list. ^ Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 721 Enter claims using DWE. See ACESII Manual, Sections 5 and 6. OWNER REFUNDS See ACESII Manual, Section 3-63 for submission procedures. For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Program Code - 97B17 Misc. Expense - REFUND Misc. Expense - ADMIN. Misc. Expense - 0.2 Hr. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order fuel sender assemblies and the gaskets through normal processing channels. PART NUMBER/DESCRIPTION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 722 Fuel Sender Assembly - NOTE: Some of the following applications will require gaskets to be ordered in addition to the sender assemblies. DEALER PRICE For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. CLAIMS PREPARATION Enter using DWE. Use code information shown below: ^ Program Code - 97B17 ^ Labor Operation Code - See Above See Sections 5 and 6 of the ACESII Manual for detailed instructions Affected Vehicle and Warning Information AFFECTED VEHICLES: CERTAIN 1997 TAURUS/SABLE, EXPLORER/MOUNTAINEER, EXPEDITION, MUSTANG AND 1998 WINDSTAR WARNING DO NOT SWALLOW GASOLINE, THESE FUELS ARE HIGHLY TOXIC AND IF SWALLOWED CAN CAUSE DEATH OR PERMANENT INJURY, SWALLOWING METHANOL CAN ALSO CAUSE BLINDNESS. CALL A PHYSICIAN IMMEDIATELY TO TREAT ANYONE WHO HAS SWALLOWED FUEL METHANOL OR FUEL ETHANOL. VOMITING SHOULD BE INDUCED BY OR UNDER THE DIRECTION OF A PHYSICIAN OR POISON CONTROL CENTER. BE AWARE THAT THE ONSET OF POTENTIAL ILL HEALTH EFFECTS MAY BE DELAYED. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 723 WARNING AVOID INHALING FUEL VAPORS. INHALING TOO MUCH FUEL VAPOR CAN LEAD TO EYE AND RESPIRATORY TRACT IRRITATION. IN SEVERE CASES, EXCESSIVE OR PROLONGED BREATHING OF FUEL VAPORS CAN CAUSE SERIOUS ILLNESS AND PERMANENT INJURY SUCH AS BLINDNESS. WARNING AVOID GETTING GASOLINE IN YOUR EYES. IF YOU GET ANY FUEL IN YOUR EYES, REMOVE CONTRACT LENSES (IF WORN), FLUSH IMMEDIATELY WITH PLENTY OF WATER FOR AT LEAST 15 MINUTES AND SEEK MEDICAL ATTENTION. WARNING IF YOU GET ANY FUEL ON YOUR SKIN, WASH WITH SOAP AND WATER. REPEATED OR PROLONGED SKIN CONTACT WITH FUEL LIQUID OR VAPOR CAUSES SKIN IRRITATION. WARNING DO NOT OPERATE ENGINE OR SMOKE WHILE REFUELING. Expedition 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Raise and support vehicle. 4. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 5. Disconnect fuel filler and vent hoses from fuel tank. Refer to Figure 1. 6. Disconnect rear EVAP hose from top of fuel tank. See Figure 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 724 7. Support fuel tank with adjustable jack. 8. Remove fuel tank straps retaining bolts. The skid plate, fuel tank and straps will be removed as an assembly. 9. Slightly lower fuel tank. 10. Disconnect fuel supply and return lines from top of fuel tank. See Figure 2. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 725 11. Disconnect fuel pump electrical connector, located between the side of the fuel tank and the frame rail. See Figure 3. 12. Slightly lower fuel tank again. 13. Disconnect front EVAP hose from top of fuel tank. 14. Remove fuel tank from vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 726 15. Clean area around fuel pump to prevent foreign material from entering fuel tank. Refer to Figure 4. 16. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel pump during reassembly. 17. Remove fuel pump lock-ring, then remove fuel pump. See Figure 4. 18. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 727 19. Disconnect fuel sender electrical connectors. Refer to Figure 5. 20. Remove fuel sender retaining screws, then remove fuel sender. See Figure 5. 21. Install new fuel sender on fuel pump. Tighten screws to 2 Nm (18 lb/in). 22. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 23. Clean fuel pump-to-gas tank mating surface. 24. Install new seal onto fuel pump-to-gas tank mating surface. 25. Install fuel pump. Align marks made during disassembly. Tighten lock-ring to 44 Nm (33 lb/ft). 26. Position fuel tank under vehicle. 27. Raise fuel tank enough to connect front EVAP hose. 28. Connect front EVAP hose. 29. Raise fuel tank enough to connect fuel lines. 30. Connect fuel supply and return lines. 31. Connect fuel pump electrical connector. 32. Raise fuel tank to installed position. 33. Install fuel tank strap retaining bolts. Tighten bolts to 46-63 Nm (33-46 lb/ft). 34. Remove jack. 35. Connect rear EVAP hose to top of fuel tank. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 728 36. Connect fuel filler and vent hoses to fuel tank. 37. Refill fuel tank. It may be necessary to refill fuel tank before connecting filler hose. 38. Lower vehicle. 39. Connect battery negative cable, then remove memory saver. 40. Stan and run engine. 41. Raise vehicle. 42. Inspect fuel system for leaks. 43. Lower vehicle. Explorer/Mountaineer 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Raise and support vehicle. 4. Remove skid plate retaining bolts, then the skid plate. 5. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 6. Support fuel tank with adjustable jack. 7. Disconnect fuel filler and vent hoses from fuel tank. 8. Remove fuel tank strap retaining bolt. 9. Remove fuel tank-to-front support bracket retaining bolts. 10. Slightly lower fuel tank. Push fuel tank back until lip of tank clears support bracket. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 729 11. Disconnect fuel supply, return and vapor lines from top of fuel tank. See Figure 6. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 730 12. Disconnect fuel pump electrical connector, located in frame rail. See Figure 7. 13. Remove fuel tank from vehicle. 14. Disconnect fuel tank pressure transducer electrical connector. Refer to Figure 8. 15. Clean area around fuel pump to prevent foreign material from entering fuel tank. 16. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel pump during assembly. 17. Remove fuel pump retaining screws, then remove fuel pump. See Figure 8. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 731 18. Disconnect fuel sender electrical connectors. Refer to Figure 9. 19. Remove fuel sender retaining screws, then remove fuel sender. See Figure 9. 20. Install new fuel sender on fuel pump. Tighten screws to 2 Nm (18 lb/in). 21. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 22. Clean fuel pump-to-gas tank mating surface. 23. Install fuel pump. Align marks made during disassembly. Tighten retaining screws to 9-12 Nm (80-107 lb/in). 24. Connect fuel tank pressure transducer electrical connector. 25. Position fuel tank under vehicle. 26. Raise fuel tank enough to connect fuel lines. 27. Connect fuel supply and return lines. 28. Connect fuel pump electrical connector. 29. Position fuel tank in installed position. 30. Install fuel tank-to-front support bracket retaining bolts. Tighten bolts to 34-46 Nm (25-34 lb/ft). 31. Install fuel tank strap retaining bolt. Tighten bolts to 34-46 Nm (25-34 lb/ft). 32. Remove jack. 33. Connect fuel filler and vent hoses to fuel tank. 34. Install skid plate. Torque retaining bolts to 34-46 Nm (25-34 lb/ft). 35. Lower vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 732 36. Fill fuel tank. 37. Connect battery negative cable, then remove memory saver. 38. Start and run engine. 39. Raise vehicle. 40. Inspect fuel system for leaks. 41. Lower vehicle. Mustang 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 4. Remove fuel filler pipe retainers from gas cap side of fuel filler pipe. 5. Raise and support vehicle. 6. Remove screw retaining fuel filler pipe retainer to fuel tank flange.Refer to Figure 10. 7. Remove fuel filler pipe rubber weather boot from inner fender well. See Figure 10. 8. Support fuel tank with adjustable jack. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 733 9. Disconnect fuel pump electrical connector. See Figure 11. 10. Remove fuel tank straps retaining bolts. 11. Slightly lower fuel tank. 12. With an assistant's help, remove filler pipe from fuel tank. The filler pipe is friction fit into the fuel tank, the filler pipe will have to be walked out of the fuel tank. See Figure 12. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 734 13. Disconnect fuel supply, return and vapor lines. See Figure 13. 14. Disconnect fuel sender electrical connector. Refer to Figure 14. 15. Remove fuel tank from vehicle. 16. Clean area around fuel sender to prevent foreign material from entering fuel tank. 17. Place alignment mark across fuel sender and fuel tank. This will assure correct alignment of fuel sender during assembly. 18. Remove fuel sender lock-ring. See Figure 14. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 735 19. Remove and discard fuel sender. 20. Remove and discard fuel sender seal. 21. Lubricate and install new fuel sender seal. 22. Install new fuel sender. Align mark made during disassembly. Tighten lock ring until it contact stops. 23. Connect fuel sender electrical connector. 24. Raise fuel tank enough to connect fuel lines. 25. Connect fuel supply, return and vapor lines. 26. Install fuel filler pipe in fuel tank. 27. Position fuel tank in installed position. 28. Install fuel tank straps. Tighten retaining bolts to 30-40 Nm (22-30 lb/ft). 29. Remove adjustable jack. 30. Connect fuel pump electrical connector. 31. Install fuel filler pipe rubber weather boot to inner fender well. 32. Install screw retaining fuel filler pipe retainer to fuel tank flange. Tighten screw to 7.3-9.0 Nm (65-80 lb/in). 33. Lower vehicle. 34. Install fuel filler pipe retainers to gas cap side of fuel filler pipe. 35. Fill fuel tank. 36. Connect battery negative cable, then remove memory saver. 37. Start and run engine. 38. Raise vehicle. 39. Inspect fuel system for leaks. 40. Lower vehicle. Taurus/Sable 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 4. Raise and support vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 736 5. Disconnect fuel filler and vent hoses from fuel tank. See Figure 15. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 737 6. Disconnect fuel supply and return lines. Refer to Figure 16. 7. Disconnect fuel pump electrical connector. See Figure 16. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 738 8. Disconnect fuel vapor line. See Figure 17. 9. Support fuel tank with adjustable jack. 10. Remove fuel tank strap retaining bolts. 11. Remove fuel tank from vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 739 12. Detach fuel pump wiring harness and fuel lines from fuel tank. Refer to Figure 18. 13. Clean area around fuel pump to prevent foreign material from entering fuel tank. 14. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel pump during assembly. 15. Disconnect fuel pressure transducer electrical connector. See Figure 18. 16. Remove fuel pump lock-ring. 17. Remove fuel pump. 18. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 740 19. Disconnect fuel sender electrical connectors. Refer to Figure 19. 20. Remove fuel sender retaining screw, then remove fuel sender. See Figure 19. 21. Install new fuel sender on fuel pump. Tighten screw to 1 Nm (9 lb/in). 22. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 23. Clean fuel pump-to-gas tank mating surface. 24. Lubricate and install new fuel pump gasket. 25. Install fuel pump. Align marks made during disassembly. Tighten lock ring until it contacts stops. 26. Install fuel pump wiring harness and fuel lines on fuel tank assembly. 27. Connect fuel pressure transducer electrical connector. 28. Install fuel tank in vehicle. Tighten fuel tank straps to 30-40 Nm (22-30 lb/ft). 29. Remove adjustable jack. 30. Connect fuel pump electrical connector. 31. Connect fuel supply, return and vapor lines. 32. Connect fuel filler and vent hoses to fuel tank. 33. Lower vehicle. 34. Fill fuel tank. 35. Connect battery negative cable, then remove memory saver. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 741 36. Start and run engine. 37. Raise vehicle. 38. Inspect fuel system for leaks. 39. Lower vehicle. Windstar 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 4. Raise and support vehicle. 5. Support fuel tank with adjustable jack. 6. Disconnect fuel filler and vent hoses from fuel tank. 7. Disconnect fuel supply, return and vapor lines. See Figure 20. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 742 8. Disconnect fuel pump electrical connector. See Figure 21. 9. Remove fuel tank straps retaining bolts. 10. Remove fuel tank from vehicle. 11. Clean area around fuel pump to prevent foreign material from entering fuel tank. 12. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel during assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 743 13. Detach fuel lines from routing clips and tie strap. See Figure 22. 14. Remove fuel pump lock-ring. 15. Remove fuel pump. 16. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 744 17. Disconnect fuel sender electrical connectors. Refer to Figure 23. 18. Remove fuel sender retaining screw, then remove fuel sender. See Figure 23. 19. Install new fuel sender on fuel pump. Tighten screw to 1 Nm (9 lb/in). 20. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 21. Clean fuel pump-to-gas tank mating surface. 22. Install new fuel pump gasket. 23. Install fuel pump. Align marks made during disassembly. Tighten lock ring until it contact stops. 24. Attach fuel lines to routing clips and install tie strap. Connect fuel lines to fuel pump. Connect electrical connector to pump/sender. 25. Install fuel tank in vehicle. Tighten fuel tank straps to 41-54 Nm (31-39 lb/ft). 26. Connect fuel pump electrical connector. 27. Connect fuel supply, return and vapor lines. 28. Connect fuel filler and vent hoses to fuel tank. 29. Remove adjustable jack. 30. Lower vehicle. 31. Fill fuel tank. 32. Connect battery negative cable, then remove memory saver. 33. Start and run engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 745 34. Raise vehicle. 35. Inspect fuel system for leaks. 36. Lower vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 746 Supplement # 1 - Attachment II LABOR ALLOWANCES Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 747 PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order fuel sender assemblies and the gaskets through normal processing channels. PART NUMBER/DESCRIPTION Fuel Sender Assembly - NOTE: Some of the following applications will require gaskets to be ordered in addition to the sender assemblies. NOTE: Kit Codes "AA" & "BB" are not used. Warning For 1997 Expedition FUEL SENDER REPLACEMENT SUPPLEMENT FOR 1997 EXPEDITION WARNING DO NOT SWALLOW GASOLINE, THESE FUELS ARE HIGHLY TOXIC AND IF SWALLOWED CAN CAUSE DEATH OR PERMANENT INJURY, SWALLOWING METHANOL CAN ALSO CAUSE BLINDNESS. CALL A PHYSICIAN IMMEDIATELY TO TREAT ANYONE WHO HAS SWALLOWED FUEL METHANOL OR FUEL ETHANOL. VOMITING SHOULD BE INDUCED BY OR UNDER THE DIRECTION OF A PHYSICIAN OR POISON CONTROL CENTER. BE AWARE THAT THE ONSET OF POTENTIAL ILL HEALTH EFFECTS MAY BE DELAYED. WARNING AVOID INHALING FUEL VAPORS. INHALING TOO MUCH FUEL VAPOR CAN LEAD TO EYE AND RESPIRATORY TRACT IRRITATION. IN SEVERE CASES, EXCESSIVE OR PROLONGED BREATHING OF FUEL VAPORS CAN CAUSE SERIOUS ILLNESS AND PERMANENT INJURY SUCH AS BLINDNESS. WARNING AVOID GETTING GASOLINE IN YOUR EYES. IF YOU GET ANY FUEL IN YOUR EYES, REMOVE CONTACT LENSES (IF WORN), FLUSH IMMEDIATELY WITH PLENTY OF WATER FOR AT LEAST 15 MINUTES AND SEEK MEDICAL ATTENTION. WARNING IF YOU GET ANY FUEL ON YOUR SKIN, WASH WITH SOAP AND WATER. REPEATED OR PROLONGED SKIN CONTACT WITH FUEL LIQUID OR VAPOR CAUSES SKIN IRRITATION. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 748 WARNING DO NOT OPERATE ENGINE OR SMOKE WHILE REFUELING. Expedition 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Raise and support vehicle. 4. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 5. Disconnect fuel filler and vent hoses from fuel tank. Refer to Figure 1. 6. Disconnect rear EVAP hose from top of fuel tank. See Figure 1. 7. Support fuel tank with adjustable jack. 8. Remove fuel tank straps retaining bolts. The skid plate, fuel tank and straps will be removed as an assembly. 9. Slightly lower fuel tank. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 749 10. Disconnect fuel supply and return lines from top of fuel tank. See Figure 2. 11. Disconnect fuel pump electrical connector, located between the side of the fuel tank and the frame rail. See Figure 3. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 750 12. Slightly lower fuel tank again. 13. Disconnect front EVAP hose from top of fuel tank. 14. Remove fuel tank from vehicle. 15. Clean area around fuel pump to prevent foreign material from entering fuel tank. Refer to Figure 4. 16. Place alignment mark across fuel pump and fuel tank. This will correctly align the fuel pump during reassembly. 17. Remove fuel pump lock-ring, then remove fuel pump. See Figure 4. 18. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 751 19. Disconnect fuel sender electrical connectors. Refer to Figure 5. 20. Remove fuel sender retaining screws, then remove fuel sender. See Figure 5. NOTE: On some vehicles this step may have already been performed. CAUTION Do not cut the main 14 gauge pump ground wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 752 21. Cut a section out of the 18 gauge black grounding wire. See Figure 6. Discard removed black wire. 22. Install new fuel sender on the fuel pump. Tighten screws to 2 Nm (18 lb/in). Note the revised orientation of the float. NOTE: There are two (2) different terminal end types used on the fuel sender ground wire, a box terminal or a ring terminal. These terminal ends are connected to different locations on the fuel sender. 23. Connect fuel sender electrical connectors as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 753 ^ Connect box type terminal end ground wire to location shown in Figure 7. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 754 ^ Connect ring type terminal end ground wire to location shown in Figure 8. ^ Reconnect yellow wire to pump sending unit harness. 24. Clean fuel pump-to-gas tank mating surface. 25. Install new seal onto fuel pump-to-gas tank mating surface. 26. Install fuel pump. Align marks made during disassembly. Tighten lock-ring to 44 Nm (33 lb/ft). 27. Position fuel tank under vehicle. 28. Raise fuel tank enough to connect front EVAP hose. 29. Connect front EVAP hose. 30. Raise fuel tank enough to connect fuel lines. 31. Connect fuel supply and return lines. 32. Connect fuel pump electrical connector. 33. Raise fuel tank to installed position. 34. Install fuel tank strap retaining bolts. Tighten bolts to 46-63 Nm (33-46 lb/ft). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 755 35. Remove jack. 36. Connect rear EVAP hose to top of fuel tank. 37. Connect fuel filler and vent hoses to fuel tank. 38. Refill fuel tank. It may be necessary to refill fuel tank before connecting filler hose. 39. Lower vehicle. 40. Connect battery negative cable, then remove memory saver. 41. Stan and run engine. 42. Raise vehicle. 43. Inspect fuel system for leaks. 44. Lower vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Service and Repair Key Reminder Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key and turn to the RUN position. 2. Press the (A) ignition switch lock cylinder release tab while pulling out the (B) ignition switch lock cylinder. 3. Remove the key in ignition warning switch. 1. Pry clip down. 2. Push key in ignition warning switch off the rear of the ignition switch lock cylinder. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Service and Repair > Page 759 2. Verify ignition switch lock cylinder operation. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations Transmission View The Digital Transmission Range Sensor is located at left side of the automatic transmission. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 764 Digital Transmission Range Sensor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 765 Backup Lamp Switch: Service and Repair The backup lamp switch is integral to the Digital Transmission Range (DTR) sensor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair Brake Light Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the Brake On/Off (BOO) switch electrical connection. 3. Remove BOO switch. 1. Remove self locking pin. 2. Remove the (A) BOO switch from the (B) brake master cylinder push rod. 3. Remove the brake master cylinder push rod spacer. 4. Remove the brake master cylinder push rod bushing. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement Technical Service Bulletin # 99B02 Date: 990301 Campaign - Multifunction Switch Replacement 99B02 OWNER NOTIFICATION PROGRAM Certain 1997-98 Expedition and 1998 Navigator Vehicles - Multifunction Switch Replacement Dealer Letter Attachment I ^ Administrative Information ^ Refund Codes Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ All Dealer Letter: Lincoln Commitment Special Handling Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 777 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 778 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator (FDCC). ^ Other eligible vehicles that are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS PREPARATION See Sections 5 & 6 of the ACESII manual for detailed instructions. OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures. For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Program Code 99B02 Misc. Expense REFUND Misc. Expense ADMIN. Misc. Expense 0.2 Hr. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 779 LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channel as noted. DEALER PRICE For latest prices, check or call your: -- Order Processing Center -- DOES II -- Updated Price Book EXCESS STOCK RETURN Excess stock return for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. CLAIMS PREPARATION -- Enter using DWE -- Use code information shown below: Program Code - 99B02 Labor Operation - See Above See Sections 5 & 6 of the ACESII manual for detailed instructions. To claim for the "Lincoln Commitment Special Handling", follow the instructions in Attachment IV. Attachment III - Technical Information TECHNICAL INSTRUCTIONS Please refer to Service Manual procedures: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 780 ^ Group 2: Chassis ^ Section 211-05: Steering Column Switches ^ Removal and Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 781 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 782 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 783 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Component Information > Locations Exterior Lighting Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Component Information > Locations > Page 786 RPO Relay Box The Park Lamp Relay is located in Regular Production Option relay block. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Combination Switch: > 98-25-21 > Dec > 98 > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement Technical Service Bulletin # 99B02 Date: 990301 Campaign - Multifunction Switch Replacement 99B02 OWNER NOTIFICATION PROGRAM Certain 1997-98 Expedition and 1998 Navigator Vehicles - Multifunction Switch Replacement Dealer Letter Attachment I ^ Administrative Information ^ Refund Codes Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ All Dealer Letter: Lincoln Commitment Special Handling Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Combination Switch: > 98-25-21 > Dec > 98 > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 796 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Combination Switch: > 98-25-21 > Dec > 98 > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 797 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator (FDCC). ^ Other eligible vehicles that are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS PREPARATION See Sections 5 & 6 of the ACESII manual for detailed instructions. OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures. For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Program Code 99B02 Misc. Expense REFUND Misc. Expense ADMIN. Misc. Expense 0.2 Hr. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Combination Switch: > 98-25-21 > Dec > 98 > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 798 LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channel as noted. DEALER PRICE For latest prices, check or call your: -- Order Processing Center -- DOES II -- Updated Price Book EXCESS STOCK RETURN Excess stock return for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. CLAIMS PREPARATION -- Enter using DWE -- Use code information shown below: Program Code - 99B02 Labor Operation - See Above See Sections 5 & 6 of the ACESII manual for detailed instructions. To claim for the "Lincoln Commitment Special Handling", follow the instructions in Attachment IV. Attachment III - Technical Information TECHNICAL INSTRUCTIONS Please refer to Service Manual procedures: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Combination Switch: > 98-25-21 > Dec > 98 > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 799 ^ Group 2: Chassis ^ Section 211-05: Steering Column Switches ^ Removal and Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Combination Switch: > 98-25-21 > Dec > 98 > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 800 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Combination Switch: > 98-25-21 > Dec > 98 > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 801 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Combination Switch: > 98-25-21 > Dec > 98 > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 802 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Specifications Hazard Warning Switch: Specifications TORQUE SPECIFICATIONS Multi-Function Switch Screws .................................................................................................................................................... 3-5 Nm (18-26 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Specifications > Page 806 Multi-Function Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Specifications > Page 807 Hazard Warning Switch: Description and Operation The Multi-function switch is mounted to the LH side of the steering column and controls the: ^ Turn signal. ^ Hazard flasher. ^ Windshield wiper/washer. ^ Rear wiper/washer. ^ Headlamp dimmer/flash-to-pass. ^ Ignition. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis Hazard Warning Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: ^ Damaged multi-function switch ^ Blown fuse(s) ^ Damaged ignition switch ^ Damaged wiring harness ^ Loose or corroded 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 810 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 811 Hazard Warning Switch: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 812 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 813 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 814 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 815 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 816 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 817 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 818 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 819 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 820 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 821 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 822 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 823 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Page 824 Hazard Warning Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Push the (A) ignition switch lock cylinder release tab with a punch while pulling out the (B) ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank and remove. 4. Release the (A) four clips and remove the (B) steering column opening cover. 5. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Page 825 (3) Remove the upper steering column shroud. 6. Remove the multi-function switch. (1) Remove the two screws. (2) Disconnect the electrical connectors. (3) Remove the multi-function switch. NOTE: The steering wheel has been removed for clarity. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Specifications Headlamp Dimmer Switch: Specifications TORQUE SPECIFICATIONS Multi-Function Switch Screws .................................................................................................................................................... 3-5 Nm (18-26 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp Dimmer Switch: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 831 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 832 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 833 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 834 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 835 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 836 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 837 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 838 Multi-Function Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 839 Headlamp Dimmer Switch: Description and Operation The Multi-function switch is mounted to the LH side of the steering column and controls the: ^ Turn signal. ^ Hazard flasher. ^ Windshield wiper/washer. ^ Rear wiper/washer. ^ Headlamp dimmer/flash-to-pass. ^ Ignition. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis Headlamp Dimmer Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: ^ Damaged multi-function switch ^ Blown fuse(s) ^ Damaged ignition switch ^ Damaged wiring harness ^ Loose or corroded 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 842 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 843 Headlamp Dimmer Switch: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 844 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 845 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 846 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 847 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 848 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 849 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 850 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 851 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 852 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 853 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 854 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 855 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 856 Headlamp Dimmer Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Push the (A) ignition switch lock cylinder release tab with a punch while pulling out the (B) ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank and remove. 4. Release the (A) four clips and remove the (B) steering column opening cover. 5. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 857 (3) Remove the upper steering column shroud. 6. Remove the multi-function switch. (1) Remove the two screws. (2) Disconnect the electrical connectors. (3) Remove the multi-function switch. NOTE: The steering wheel has been removed for clarity. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams Headlamp Switch: Diagrams Main Light Switch Main Light Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 861 Main Light Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 862 Headlamp Switch: Testing and Inspection Main Light Switch - Component Testing Procedure Main Light Switch - Terminal Location Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 863 Main Light Switch - Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Headlamp Switch Headlamp Switch: Service and Repair Headlamp Switch REMOVAL 1. Disconnect the battery ground cable. 2. Turn the headlamp switch knob to the headlamp position and pull the knob. 3. Insert a thin tool to release the headlamp switch knob and remove. 4. Turn the headlamp switch knob 180 degrees and install. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Headlamp Switch > Page 866 5. Turn counterclockwise until the back of the headlamp switch knob is in the off position. 6. Turn the headlamp switch knob clockwise fully. 7. Remove the headlamp switch. 1. Pull headlamp switch from instrument panel. 2. Disconnect the electrical connectors. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive system may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications Turn Signal Switch: Specifications TORQUE SPECIFICATIONS Multi-Function Switch Screws .................................................................................................................................................... 3-5 Nm (18-26 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 870 Multi-Function Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 871 Turn Signal Switch: Description and Operation The Multi-function switch is mounted to the LH side of the steering column and controls the: ^ Turn signal. ^ Hazard flasher. ^ Windshield wiper/washer. ^ Rear wiper/washer. ^ Headlamp dimmer/flash-to-pass. ^ Ignition. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis Turn Signal Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: ^ Damaged multi-function switch ^ Blown fuse(s) ^ Damaged ignition switch ^ Damaged wiring harness ^ Loose or corroded 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 874 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 875 Turn Signal Switch: Pinpoint Tests Pinpoint Test Step Icons Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 876 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 877 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 878 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 879 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 880 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 881 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 882 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 883 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 884 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 885 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 886 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 887 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Page 888 Turn Signal Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Push the (A) ignition switch lock cylinder release tab with a punch while pulling out the (B) ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank and remove. 4. Release the (A) four clips and remove the (B) steering column opening cover. 5. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Page 889 (3) Remove the upper steering column shroud. 6. Remove the multi-function switch. (1) Remove the two screws. (2) Disconnect the electrical connectors. (3) Remove the multi-function switch. NOTE: The steering wheel has been removed for clarity. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 900 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 901 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 907 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 908 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor Assembly Replacement Air Flow Meter/Sensor: All Technical Service Bulletins Mass Air Flow Sensor - Assembly Replacement Article No. 96-22-5 10/21/96 MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP FORD: 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR, EXPLORER, RANGER 1993-97 VILLAGER 1994-96 BRONCO 1994-97 ECONOLINE 1995-97 F-150, WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: The Mass Air Flow (MAF) sensor is not designed to be removed from its body (die-cast or plastic) for servicing. The sensing elements located inside the by-pass tube can be damaged by poking/probing/touching. ACTION: Service the MAF sensor as an assembly (refer to Figure 1). WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor Assembly Replacement > Page 913 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement Air Flow Meter/Sensor: All Technical Service Bulletins Mass Air Flow Sensor - Assembly Replacement Article No. 96-22-5 10/21/96 MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP FORD: 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR, EXPLORER, RANGER 1993-97 VILLAGER 1994-96 BRONCO 1994-97 ECONOLINE 1995-97 F-150, WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: The Mass Air Flow (MAF) sensor is not designed to be removed from its body (die-cast or plastic) for servicing. The sensing elements located inside the by-pass tube can be damaged by poking/probing/touching. ACTION: Service the MAF sensor as an assembly (refer to Figure 1). WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement > Page 919 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 920 Air Flow Meter/Sensor: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 921 RH Component The Mass Air Flow Sensor is located in air cleaner assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 922 Air Flow Meter/Sensor: Description and Operation PURPOSE The Mass Air Flow (MAF) sensor: - Sends the PCM a signal indicating mass airflow rate of air entering the engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal Air Flow Meter/Sensor: Service and Repair Removal REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Open the engine air cleaner. - Disconnect the Mass Air Flow (MAF) sensor connector from the wiring harness. - Release the air cleaner clamp. Separate the inlet side of the air cleaner from the outlet side of the air cleaner. 3. Cut the tape on the wire loom of the extension harness. CAUTION: Do not cut the MAF sensor wires when cutting the tape on the wire loom. - Peel back the wire loom from the extension harness near the grommet in the air cleaner. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal > Page 925 4. Remove the grommet from the outlet side of the air cleaner and slide the grommet down the extension harness. 5. Remove the MAF sensor plate and MAF sensor from the outlet side of the engine air cleaner. 6. Disconnect the MAF sensor electrical connector. 7. Remove the nuts and separate the MAF plate from the MAF sensor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal > Page 926 Air Flow Meter/Sensor: Service and Repair Installation INSTALLATION CAUTION: - Do not tamper with the MAF sensing elements located in the airflow bypass; tampering may result in unit failure. - The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. NOTE: - Use the alignment notch to properly align the inlet side and the outlet side of the engine air cleaner. - The MAF sensor module and body are calibrated and replaced as a unit. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt 8-12 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 930 Camshaft Position Sensor: Locations Engine View The Camshaft Position Sensor is located in front of the engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 931 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 932 Camshaft Position Sensor: Description and Operation The Camshaft Position (CMP) sensor: - Sends the PCM a signal indicating camshaft position, which is used for fuel synchronization. NOTE: The Camshaft Position (CMP) sensor is also referred to as Cylinder Identification Sensor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 933 Camshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the CMP sensor. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Coolant Temperature Sensor Coolant Temperature Sensor/Switch (For Computer): Locations Coolant Temperature Sensor Engine View The Engine Coolant Temperature Sensor is located in front of the engine. NOTE: In some applications of the 4.6L engine, the Cylinder Head Temperature (CHT) sensor provides the signal used by the Powertrain Control Module (PCM) in place of the Coolant Temperature Sensor (CTS) for functions such as, but not limited to, activating the electric cooling fans. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Coolant Temperature Sensor > Page 938 Engine Views Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 939 Coolant Temperature Sensor/Switch (For Computer): Description and Operation The Engine Coolant Temperature (ECT) sensor: - Sends the PCM a signal indicating engine temperature. - Resistance decreases as coolant temperature increases. NOTE: In some applications of the 4.6L engine, the Cylinder Head Temperature (CHT) sensor provides the signal used by the Powertrain Control Module (PCM) in place of the Coolant Temperature Sensor (CTS) for functions such as, but not limited to, activating the electric cooling fans. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 940 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Partially drain the cooling system. 3. Remove the Engine Coolant Temperature (ECT) sensor . 1 Disconnect the electrical connector. 2 Remove the ECT sensor. INSTALLATION 1. Install the ECT. 2. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Retainer Torque 8-12 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 944 Crankshaft Position Sensor: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 945 The Crankshaft Position Sensor is located at the lower front of engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 946 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) sensor: - Sends the PCM a signal indicating crankshaft position. - Is essential for calculating spark timing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 947 Crankshaft Position Sensor: Service and Repair REMOVAL WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 3. Release the tension on the accessory drive belt. 1. Remove the A/C compressor. 1 Remove the A/C compressor bolts. 2 Remove the A/C compressor and position aside. NOTE: Do not remove lines from the A/C compressor. 5. Remove the (A) CKP sensor bolt and the (B) CKP sensor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 948 To install, reverse the removal procedure NOTE:If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications Engine Temperature Sensor: Specifications Cylinder Head Temperature (CHT) Sensor 25 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 952 Engine Temperature Sensor: Locations Engine View The Cylinder Head Temperature Sensor is located at top front of the engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 953 Engine Temperature Sensor: Description and Operation FEATURES The Cylinder Head Temperature (CHT) sensor: - Is mounted into the wall of the cylinder head and is not connected to any coolant passages. Sends a signal to the PCM indicating the cylinder head temperature. - If the temperature exceeds: 130°C (265°F) the PCM disables four fuel injectors at a time. The PCM will alternate which four injectors are disabled every 32 engine cycles. The four cylinders that are not being fuel injected act as air pumps to aid in cooling the engine. - If the temperature exceeds: 166°C (330°F) the PCM disables all of the fuel injectors until the engine temperature drops below: 153°C (308°F) - If the engine reaches critical temperature, the following happens: - The coolant temperature gauge pointer will read fully hot at 121°C (250°F). - The check gauge warning indicator will illuminate. - DTCs are set. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 954 Engine Temperature Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the Cylinder Head Temperature (CHT) sensor. 1 Disconnect the electrical connector. 2 Remove the CHT sensor. INSTALLATION 1. Install the CHT. 2. Install the intake manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure (FTP) Sensor PURPOSE The Fuel Tank Pressure (FTP) sensor (A) is used to monitor the fuel tank pressure or vacuum during the OBD II purge monitor test of the Evaporative Emission System for Running Loss vehicles (passenger cars with fuel vapor control valves and trucks with fuel vapor valves). This monitor also performs a fuel system integrity check to determine if there is an evaporative emission system leak. Variations in pressure will be converted into an analog voltage input signal to the PCM. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 961 Engine View The Intake Air Temperature Sensor is located on the air intake tube. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 962 Intake Air Temperature Sensor: Description and Operation PURPOSE The Intake Air Temperature (IAT) sensor: - Sends the PCM a signal indicating the temperature of the air entering the engine. - It's resistance decreases as temperature increases. - The PCM uses the air temperature information as a correction factor in the calculation of fuel, spark and MAF. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 963 Intake Air Temperature Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 3. Remove the IAT sensor. INSTALLATION To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor 20-27 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 967 Knock Sensor: Description and Operation The knock sensor is located in the lifter valley and: - Sends a signal to the PCM indicating engine detonation. - If detonation is occurring, the PCM then changes engine timing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 968 Knock Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the Knock Sensor (KS) . 1 Disconnect the electrical connector. 2 Remove the KS. INSTALLATION 1. Install the Knock Sensor (KS) 1 Install the KS. 2 Connect the electrical connector. 2. Install the intake manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns Oxygen Sensor: Customer Interest PCM - MIL ON/Multiple DTC's Set/Driveability Concerns Article No. 97-26-19 12/22/97 ^ HESITATION/SURGE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ MALFUNCTION INDICATOR LAMP (MIL) - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 ^ ROUGH IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ STALL - LOW SPEEDS AND OR IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 F-350, NAVIGATOR This TSB article is being republished in its entirety to correct the PCM Application Chart and include a reference to TSB 97-26-17. CALIBRATION: 7-46D-R07, 7-46E-R07, 7-46F-R07, 7-46R-R07, 7-46T-R07, 7-46U-R07, 7-46F-R10, 7-46U-R10, 7-48J-R05, 7-48U-R05, 7-48J-R10, 7-48U-R10, 8-46D-R05, 8-46E-R05, 8-46F-R05, 8-46R-RO5, 8-46T-R05, 8-46U-R05, 8-48J-R05 WARNING: THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS. ISSUE: The Malfunction Indicator Lamp (MIL) may illuminate on vehicles with a 4.6L or 5.4L engine, and one or more of the following concerns may be present: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 977 ^ MIL lamp on with Diagnostic Trouble Codes (DTCs): P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 ^ Rough idle ^ Engine miss ^ Hesitation/Surge ^ Buck/Jerk ^ Stall at idle ^ Near stall ^ Stall at low speeds This may be caused by the Heated Exhaust Gas Oxygen (HEGO) monitor calibration not allowing enough time for proper monitoring. ACTION: Reprogram the Powertrain Control Module (PCM) and replace the HEGO sensor(s). Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal diagnostics as outlined in the 1997 Powertrain Control/Emissions Diagnosis (PC/ED) On-Board Diagnostics II (OBD-II) Service Manual and repair as required. 2. If the concern still exists or no problems were found, reprogram the PCM using Service Bay Diagnostic System (SDBS) or New Generation Star (NGS) Tester. Refer to the following Recalibration Cross Reference Chart for correct PCM calibration. 3. Replace the HEGO sensor(s) (F88z-9F472-AB) as required. NOTE: FOR 5.4L APPLICATIONS, DEALERS MUST ALSO PERFORM TSB 97-26-17 TO INSTALL THE DRAIN TUBE ON THE LOWER A/C EVAPORATOR DRAIN. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 978 NOTE: PCM REPLACEMENT IS NOT AUTHORIZED BY THIS TSB. REFER TO THE POWERTRAIN CONTROL/EMISSIONS DIAGNOSIS (PC/ED) SERVICE MANUAL FOR APPROPRIATE DIAGNOSTIC PROCEDURES IF PCM HARDWARE CONCERNS EXIST. Obtain an Authorized Modification Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME F88Z-9F472-AB Heated Exhaust Gas Oxygen (HEGO) Sensor OTHER APPLICABLE ARTICLES: 97-26-17 SUPERSEDES: 97-21-13 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 972619A Reprogram Powertrain 0.2 Hr. Control Module (PCM) 972619DL Replace Heated Exhaust 0.3 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Left Side 972619DR Replace Heated Exhaust 0.6 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Right Side 972619DT Replace Heated Exhaust 0.8 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Both 972619ET Replace Heated Exhaust 0.4 Hr. Gas Oxygen (HEGO) Sensors - 4.6L Both 972619E Replace Heated Exhaust 0.3 Hr. Gas Oxygen (H EGO) Sensors - 4.6L One DEALER CODING CONDITION BASIC PART NO. CODE 9F472 42 OASIS CODES: 607000, 607400, 607700, 608000, 608400, Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 979 611000, 611500, 612000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 985 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 986 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 987 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 988 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 989 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 990 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 991 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 992 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 993 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 994 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 995 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 996 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 997 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 998 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 999 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns Oxygen Sensor: All Technical Service Bulletins PCM - MIL ON/Multiple DTC's Set/Driveability Concerns Article No. 97-26-19 12/22/97 ^ HESITATION/SURGE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ MALFUNCTION INDICATOR LAMP (MIL) - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 ^ ROUGH IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ STALL - LOW SPEEDS AND OR IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 F-350, NAVIGATOR This TSB article is being republished in its entirety to correct the PCM Application Chart and include a reference to TSB 97-26-17. CALIBRATION: 7-46D-R07, 7-46E-R07, 7-46F-R07, 7-46R-R07, 7-46T-R07, 7-46U-R07, 7-46F-R10, 7-46U-R10, 7-48J-R05, 7-48U-R05, 7-48J-R10, 7-48U-R10, 8-46D-R05, 8-46E-R05, 8-46F-R05, 8-46R-RO5, 8-46T-R05, 8-46U-R05, 8-48J-R05 WARNING: THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS. ISSUE: The Malfunction Indicator Lamp (MIL) may illuminate on vehicles with a 4.6L or 5.4L engine, and one or more of the following concerns may be present: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 1004 ^ MIL lamp on with Diagnostic Trouble Codes (DTCs): P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 ^ Rough idle ^ Engine miss ^ Hesitation/Surge ^ Buck/Jerk ^ Stall at idle ^ Near stall ^ Stall at low speeds This may be caused by the Heated Exhaust Gas Oxygen (HEGO) monitor calibration not allowing enough time for proper monitoring. ACTION: Reprogram the Powertrain Control Module (PCM) and replace the HEGO sensor(s). Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal diagnostics as outlined in the 1997 Powertrain Control/Emissions Diagnosis (PC/ED) On-Board Diagnostics II (OBD-II) Service Manual and repair as required. 2. If the concern still exists or no problems were found, reprogram the PCM using Service Bay Diagnostic System (SDBS) or New Generation Star (NGS) Tester. Refer to the following Recalibration Cross Reference Chart for correct PCM calibration. 3. Replace the HEGO sensor(s) (F88z-9F472-AB) as required. NOTE: FOR 5.4L APPLICATIONS, DEALERS MUST ALSO PERFORM TSB 97-26-17 TO INSTALL THE DRAIN TUBE ON THE LOWER A/C EVAPORATOR DRAIN. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 1005 NOTE: PCM REPLACEMENT IS NOT AUTHORIZED BY THIS TSB. REFER TO THE POWERTRAIN CONTROL/EMISSIONS DIAGNOSIS (PC/ED) SERVICE MANUAL FOR APPROPRIATE DIAGNOSTIC PROCEDURES IF PCM HARDWARE CONCERNS EXIST. Obtain an Authorized Modification Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME F88Z-9F472-AB Heated Exhaust Gas Oxygen (HEGO) Sensor OTHER APPLICABLE ARTICLES: 97-26-17 SUPERSEDES: 97-21-13 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 972619A Reprogram Powertrain 0.2 Hr. Control Module (PCM) 972619DL Replace Heated Exhaust 0.3 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Left Side 972619DR Replace Heated Exhaust 0.6 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Right Side 972619DT Replace Heated Exhaust 0.8 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Both 972619ET Replace Heated Exhaust 0.4 Hr. Gas Oxygen (HEGO) Sensors - 4.6L Both 972619E Replace Heated Exhaust 0.3 Hr. Gas Oxygen (H EGO) Sensors - 4.6L One DEALER CODING CONDITION BASIC PART NO. CODE 9F472 42 OASIS CODES: 607000, 607400, 607700, 608000, 608400, Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 1006 611000, 611500, 612000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 1012 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 1013 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 1014 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 1015 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 1016 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 1017 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 1018 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 1019 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 1020 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 1021 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 1022 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 1023 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 1024 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 1025 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 1026 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 1027 Oxygen Sensor: Specifications Heated Oxygen Sensor 36-46 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > OBD-II Heated Oxygen Sensor Numbering Convention Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > OBD-II Heated Oxygen Sensor Numbering Convention > Page 1030 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1033 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1034 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1035 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1036 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1037 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1038 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1039 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1040 Oxygen Sensor: Connector Views Vehicle Harness Connector Connector Test Pin Numbers Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 1041 HO2S Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 1042 Oxygen Sensor: Description and Operation UPSTREAM HEATED OXYGEN (HO2S) SENSOR: - Has the ability to create a voltage signal dependent on exhaust oxygen content. - Provides feedback information to the PCM used to calculate fuel delivery. - Is positioned in the exhaust manifold outlet. DOWNSTREAM HEATED OXYGEN (HO2S) SENSOR: - Monitors oxygen content after the catalytic converter. - Provides a voltage to the PCM used to calculate catalytic converter integrity. - Is also referred to as the Catalyst Monitor Sensor (CMS). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Upstream Heated Oxygen Sensor Oxygen Sensor: Service and Repair Upstream Heated Oxygen Sensor REMOVAL WARNING: - The normal operating temperature of the exhaust system is very high. never attempt to service any part of the system until it has cooled. Be especially careful when working around the three way catalytic converter. The temperature of the three way catalytic converter rises to a high level after only a few minutes of engine operation. - The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by tuning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. 1. Turn the ignition key off. 2. Disconnect the two Heated Oxygen Sensor (HO2S) electrical connectors. 3. Raise and support the vehicle. 4. Use Oxygen Sensor Wrench to remove the LH and RH HO2Ss. INSTALLATION To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Upstream Heated Oxygen Sensor > Page 1045 Oxygen Sensor: Service and Repair Downstream Heated Oxygen Sensor REMOVAL WARNING: - The normal operating temperature of the exhaust system is very high. Never attempt to service any part of the system until it has cooled. Be especially careful when working around the three way catalytic converter. The temperature of the three way catalytic converter rises to a high level after only a few minutes of engine operation. - The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by tuning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. 1. Turn the ignition key off. 2. Raise and support the vehicle. 3. Remove the Catalyst Monitor Sensor (CMS). 1 Disconnect the electrical connector. 2 Use Oxygen Sensor Wrench to remove the CMS. INSTALLATION To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Page 1046 Oxygen Sensor: Tools and Equipment Oxygen Sensor Wrench T94 - P-9472-A Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision Pressure Feedback Exhaust Sensor: Technical Service Bulletins EGR DPFE Sensor - Voltage Range Revision Article No. 97-22-1 10/27/97 DELTA PRESSURE FEEDBACK EGR (DPFE) - DIAGNOSTIC TIPS FORD: 1994-97 MUSTANG, THUNDERBIRD 1995-97 CONTOUR, CROWN VICTORIA 1996-97 ESCORT, TAURUS LINCOLN-MERCURY: 1990-97 TOWN CAR 1994-97 COUGAR 1995-97 CONTINENTAL, GRAND MARQUIS, MYSTIQUE 1996-97 SABLE, TRACER LIGHT TRUCK: 1994-97 EXPLORER 1995-97 ECONOLINE, F-150-350 SERIES, WINDSTAR 1996-97 AEROSTAR 1997 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: The current DPFE sensor diagnostic reference values as published in the Powertrain Control/Emissions Diagnosis (PC/ED) Service Manual, and also accessed by either the Service Bay Diagnostic System (SBDS) or Service Bay Technical System (SBTS), can lead to the replacement of good DPFE sensors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision > Page 1051 ACTION: Use the following revised DPFE sensor voltage ranges for all (black plastic or aluminum) DPFE system applications when checking the PID (Parameter Identifier Display) value "DPFEGR" or when measuring the DPFE sensor input directly at the breakout box. Refer to Figure 1. NOTE: THESE LISTED VOLTAGE RANGES SHOULD BE USED FOR ALL (BLACK PLASTIC OR ALUMINUM) DPFE SYSTEM APPLICATIONS WHENEVER CHECKING THE PID VALUE "DPFEGR" OR WHEN MEASURING THE DPFE SENSOR INPUT DIRECTLY AT THE BREAKOUT BOX. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 1052 Pressure Feedback Exhaust Sensor: Locations Engine View The Differential Pressure Feedback EGR (DPFE) Sensor is located at the right side of engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Retaining Screws 2.8-3.4 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 1056 Throttle Position Sensor: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 1057 The Throttle Position Sensor is attached to the throttle body. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 1058 Throttle Position Sensor: Description and Operation PURPOSE The Throttle Position Sensor (TP): - Sends the PCM a signal indicating the throttle plate angle. - Is the main input to the PCM from the driver. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 1059 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Remove the accelerator control splash shield. 1 Remove three accelerator splash shield bolts. 2 Remove the accelerator control splash shield from the vehicle. 3. Remove the Throttle Position (TP) sensor. 1 Disconnect the electrical connector. 2 Remove the two bolts. 3 Remove the TP sensor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 1060 To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > New Digital Transmission Range Sensor - Service Tip Transmission Position Switch/Sensor: Technical Service Bulletins New Digital Transmission Range Sensor - Service Tip Article No. 96-24-10 11/18/96 TRANSMISSION - E40D - 4R70W - 4R44E - 5R55E - NEW DIGITAL TRANSMISSION RANGE SENSOR - DIAGNOSIS SERVICE TIP LINCOLN-MERCURY: 1997 MARK VIII LIGHT TRUCK: 1997 AEROSTAR, ECONOLINE, EXPEDITION, EXPLORER, F-150, F-250, MOUNTAINEER ISSUE: Beginning with Job 1 1997, some vehicles will be equipped with a new Digital Transmission Range (DTR) sensor. The DTR sensor is located on the outside of the transmission (Figure 1) at the outer manual lever. ACTION: Refer to the following text to properly diagnose a concern with the DTR sensor. The new DTR sensor completes the start circuit in "Park" and "Neutral," the backup lamp circuit in "Reverse" and the neutral sense circuit (4X4 only) in "Neutral." The DTR sensor also opens/closes a set of four (4) switches that are monitored by the Powertrain Control Module (PCM) to determine the position of the transmission manual lever. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > New Digital Transmission Range Sensor - Service Tip > Page 1065 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > New Digital Transmission Range Sensor - Service Tip > Page 1066 To properly diagnose the DTR sensor, use the NGS, Rotunda Transmission Tester with TR/MLP Cable "E" (Figure 2) and the new DTR Sensor Overlay (Figure 4), while following the procedures outlined in the appropriate model 1997 Service Manual, Section 07-01 or appropriate model 1997 Workshop Manual, Section 307-01. The new DTR Sensor Overlay (007-00131) and updated Tester Manual was sent to all dealers in August 1996. The TR/MLP Cable "E" (007-00111) was sent to all dealers in June 1995 (refer to TSB 95-19-7). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > New Digital Transmission Range Sensor - Service Tip > Page 1067 When using Cable "E" (Figure 3) to diagnose the DTR sensor, the slide switch must be in the "Digital" position and the "Black" 12-pin connector installed on the sensor. Having the slide switch in the incorrect position or using the incorrect 12-pin connector will result in misdiagnosis and possible replacement of a good component. For diagnosis of the DTR sensor, always refer to the appropriate model 1997 Service Manual, Section 07.01 or appropriate model 1997 Workshop Manual, Section 3O7-01 for proper procedure and required equipment. OTHER APPLICABLE ARTICLES: 95-19-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 503000, 503300, 504000, 601300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 1068 Transmission Position Switch/Sensor: Specifications TORQUE SPECIFICATIONS DTR Sensor Bolts ................................................................................................................................ ..................................... 7-10 Nm (62-89 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 1069 Transmission Position Switch/Sensor: Locations Transmission View The Digital Transmission Range Sensor is located at left side of the automatic transmission. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 1070 Digital Transmission Range Sensor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 1071 Transmission Position Switch/Sensor: Adjustments NOTE: Use Digital Transmission Range (DTR) Sensor Alignment Tool to align both TR and DTR sensors. 1. Raise and support vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Disconnect the manual lever shift control cable. 3. Disconnect the TR or DTR electrical connector. 4. Remove the manual control lever. (1) Remove the nut. (2) Remove the lever. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. 5. Loosen the TR or DTR bolts. 6. Use DTR sensor alignment tool, to align the DTR or TR sensor slots. NOTE: Manual shift lever must be in the neutral position. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 1072 7. Tighten the DTR or TR sensor bolts. 8. Install the manual control lever. (1) Position the manual control lever. (2) Install a new manual lever shaft outer nut. 9. With the manual lever in overdrive connect the shift lever control cable. 10. Install the DTR sensor electrical connector. 11. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications TORQUE SPECIFICATIONS Vehicle Speed Sensor (VSS) Bolt ........................................................................................................................................ 11-13 Nm (98-115 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 1076 Vehicle Speed Sensor: Locations Transmission View The Vehicle Speed Sensor is located at left rear of transmission. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1079 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1080 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1081 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1082 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1083 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1084 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1085 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 1086 Vehicle Speed Sensor: Description and Operation Purpose The Vehicle Speed (VSS) Sensor: - Is gear driven by the transmission. - Sends a signal to the PCM indicating transmission speed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 1087 Vehicle Speed Sensor: Service and Repair REMOVAL 1. Disconnect the battery. 2. Raise and support the vehicle. WARNING: The electrical power to the air suspension system must be shut OFF prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning OFF the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during 1 these operations. 3. Remove the Vehicle Speed Sensor (VSS). (1) Disconnect the electrical connector. (2) Remove the bolt. (3) Remove the VSS. 4. Remove the Vehicle Speed Sensor (VSS) drive gear. INSTALLATION 1. Install the Vehicle Speed Sensor (VSS) drive gear. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 1088 2. Install the VSS. (1) Install the VSS. (2) Install the bolt. (3) Connect the electrical connector. 3. Remove supports and lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning ON the air suspension switch. 4. Reconnect the battery ground cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Leak Detection Sensor, Evaporative System > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Leak Detection Sensor, Evaporative System > Component Information > Diagrams > Page 1093 Leak Detection Sensor: Description and Operation Fuel Tank Pressure (FTP) Sensor FUEL TANK PRESSURE SENSOR The Fuel Tank Pressure (FTP) sensor (A) is used to monitor the fuel tank pressure or vacuum during the OBD II purge monitor test of the Evaporative Emission System for Running Loss vehicles (passenger cars with fuel vapor control valves and trucks with fuel vapor valves). This monitor also performs a fuel system integrity check to determine if there is an evaporative emission system leak. Variations in pressure will be converted into an analog voltage input signal to the PCM. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision Pressure Feedback Exhaust Sensor: Technical Service Bulletins EGR DPFE Sensor - Voltage Range Revision Article No. 97-22-1 10/27/97 DELTA PRESSURE FEEDBACK EGR (DPFE) - DIAGNOSTIC TIPS FORD: 1994-97 MUSTANG, THUNDERBIRD 1995-97 CONTOUR, CROWN VICTORIA 1996-97 ESCORT, TAURUS LINCOLN-MERCURY: 1990-97 TOWN CAR 1994-97 COUGAR 1995-97 CONTINENTAL, GRAND MARQUIS, MYSTIQUE 1996-97 SABLE, TRACER LIGHT TRUCK: 1994-97 EXPLORER 1995-97 ECONOLINE, F-150-350 SERIES, WINDSTAR 1996-97 AEROSTAR 1997 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: The current DPFE sensor diagnostic reference values as published in the Powertrain Control/Emissions Diagnosis (PC/ED) Service Manual, and also accessed by either the Service Bay Diagnostic System (SBDS) or Service Bay Technical System (SBTS), can lead to the replacement of good DPFE sensors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision > Page 1098 ACTION: Use the following revised DPFE sensor voltage ranges for all (black plastic or aluminum) DPFE system applications when checking the PID (Parameter Identifier Display) value "DPFEGR" or when measuring the DPFE sensor input directly at the breakout box. Refer to Figure 1. NOTE: THESE LISTED VOLTAGE RANGES SHOULD BE USED FOR ALL (BLACK PLASTIC OR ALUMINUM) DPFE SYSTEM APPLICATIONS WHENEVER CHECKING THE PID VALUE "DPFEGR" OR WHEN MEASURING THE DPFE SENSOR INPUT DIRECTLY AT THE BREAKOUT BOX. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 1099 Pressure Feedback Exhaust Sensor: Locations Engine View The Differential Pressure Feedback EGR (DPFE) Sensor is located at the right side of engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 1109 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 1110 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 1116 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 1117 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement Air Flow Meter/Sensor: All Technical Service Bulletins Mass Air Flow Sensor - Assembly Replacement Article No. 96-22-5 10/21/96 MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP FORD: 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR, EXPLORER, RANGER 1993-97 VILLAGER 1994-96 BRONCO 1994-97 ECONOLINE 1995-97 F-150, WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: The Mass Air Flow (MAF) sensor is not designed to be removed from its body (die-cast or plastic) for servicing. The sensing elements located inside the by-pass tube can be damaged by poking/probing/touching. ACTION: Service the MAF sensor as an assembly (refer to Figure 1). WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement > Page 1122 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement Air Flow Meter/Sensor: All Technical Service Bulletins Mass Air Flow Sensor - Assembly Replacement Article No. 96-22-5 10/21/96 MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP FORD: 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR, EXPLORER, RANGER 1993-97 VILLAGER 1994-96 BRONCO 1994-97 ECONOLINE 1995-97 F-150, WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: The Mass Air Flow (MAF) sensor is not designed to be removed from its body (die-cast or plastic) for servicing. The sensing elements located inside the by-pass tube can be damaged by poking/probing/touching. ACTION: Service the MAF sensor as an assembly (refer to Figure 1). WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement > Page 1128 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 1129 Air Flow Meter/Sensor: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 1130 RH Component The Mass Air Flow Sensor is located in air cleaner assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 1131 Air Flow Meter/Sensor: Description and Operation PURPOSE The Mass Air Flow (MAF) sensor: - Sends the PCM a signal indicating mass airflow rate of air entering the engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal Air Flow Meter/Sensor: Service and Repair Removal REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Open the engine air cleaner. - Disconnect the Mass Air Flow (MAF) sensor connector from the wiring harness. - Release the air cleaner clamp. Separate the inlet side of the air cleaner from the outlet side of the air cleaner. 3. Cut the tape on the wire loom of the extension harness. CAUTION: Do not cut the MAF sensor wires when cutting the tape on the wire loom. - Peel back the wire loom from the extension harness near the grommet in the air cleaner. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal > Page 1134 4. Remove the grommet from the outlet side of the air cleaner and slide the grommet down the extension harness. 5. Remove the MAF sensor plate and MAF sensor from the outlet side of the engine air cleaner. 6. Disconnect the MAF sensor electrical connector. 7. Remove the nuts and separate the MAF plate from the MAF sensor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal > Page 1135 Air Flow Meter/Sensor: Service and Repair Installation INSTALLATION CAUTION: - Do not tamper with the MAF sensing elements located in the airflow bypass; tampering may result in unit failure. - The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. NOTE: - Use the alignment notch to properly align the inlet side and the outlet side of the engine air cleaner. - The MAF sensor module and body are calibrated and replaced as a unit. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations Inertia Fuel Shutoff Switch: Locations The inertia fuel shutoff switch is located under the RH cowl side trim (kick) panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 1139 Inertia Fuel Shutoff Switch: Service Precautions WARNING: Do not reset the Inertia Fuel Shutoff switch (IFS) switch until the complete fuel system has been inspected for leaks. Damage to the vehicle or personal injury may occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 1140 Inertia Fuel Shutoff Switch: Description and Operation Typical Inertia Fuel Shut-Off Switch Description The inertia fuel shutoff switch: - is used in conjunction with an electric fuel pump. - shuts off the fuel pump in the event of a collision. - consists of a steel ball held in place by a magnet. Operation When a sharp impact occurs: - the ball breaks loose from the magnet, rolls up a ramp and strikes a target plate which opens the electrical contacts of the inertia fuel shutoff switch and shuts off the fuel pump. - Once the inertia fuel shutoff switch is open, the inertia fuel shutoff switch must be manually reset before restarting the vehicle. If a collision occurs: - the electrical contacts in the inertia fuel shutoff switch open. - the fuel pump automatically shuts off, even if the engine does not stop running. - the engine will stop a few seconds after the fuel pump stops. - it is impossible to restart engine until the inertia fuel shutoff switch, located on the LH side lower back panel in the luggage compartment, is manually reset. NOTE:In the reset position, the button can be pressed an additional 1.59 mm (0.0625 inch) against a spring. This is a normal condition. WARNING: Do not reset the inertia fuel shutoff switch until the complete fuel system has been inspected for leaks or damage to vehicle or personal injury may occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 1141 Inertia Fuel Shutoff Switch: Testing and Inspection To avoid potential misdiagnosis and the unnecessary replacement of components, it is recommended that diagnosis and testing begin with Diagnostic Routines (Diagnosis by Symptom) at the Powertrain Management level. The Diagnostic Routines will lead the technician through the logical and methodical testing of a "specific" subsystem and it's related wiring and components. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 1142 Inertia Fuel Shutoff Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Remove the RH cowl side trim panel. 3. Disconnect the inertia fuel shutoff switch electrical connector. 4. Remove the inertia fuel shutoff switch. 1 Remove inertia switch bolts. 2 Remove the inertia fuel shutoff switch. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 1143 To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Specifications Oil Pressure Switch (For Fuel Pump): Specifications Oil Pressure Switch 12-16 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Specifications > Page 1147 Oil Pressure Switch (For Fuel Pump): Testing and Inspection To avoid potential misdiagnosis and the unnecessary replacement of components, it is recommended that diagnosis and testing begin with Diagnostic Routines (Diagnosis by Symptom) at the Powertrain Management level. The Diagnostic Routines will lead the technician through the logical and methodical testing of a "specific" subsystem and it's related wiring and components. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Specifications > Page 1148 Oil Pressure Switch (For Fuel Pump): Service and Repair REMOVAL 1. Disconnect the oil pressure switch electrical connector. 2. Remove the oil pressure switch from the oil filter adapter. INSTALLATION 1. To install, reverse the removal procedure. 2. Check the oil level and fill to specification with Ford Premium SAE 1OW-30 Motor Oil XO-1OW-30-BSP, DSP, QSP or equivalent meeting Ford specification ESE-M2C153-E. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Retaining Screws 2.8-3.4 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 1152 Throttle Position Sensor: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 1153 The Throttle Position Sensor is attached to the throttle body. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 1154 Throttle Position Sensor: Description and Operation PURPOSE The Throttle Position Sensor (TP): - Sends the PCM a signal indicating the throttle plate angle. - Is the main input to the PCM from the driver. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 1155 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Remove the accelerator control splash shield. 1 Remove three accelerator splash shield bolts. 2 Remove the accelerator control splash shield from the vehicle. 3. Remove the Throttle Position (TP) sensor. 1 Disconnect the electrical connector. 2 Remove the two bolts. 3 Remove the TP sensor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 1156 To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt 8-12 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 1161 Camshaft Position Sensor: Locations Engine View The Camshaft Position Sensor is located in front of the engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 1162 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 1163 Camshaft Position Sensor: Description and Operation The Camshaft Position (CMP) sensor: - Sends the PCM a signal indicating camshaft position, which is used for fuel synchronization. NOTE: The Camshaft Position (CMP) sensor is also referred to as Cylinder Identification Sensor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 1164 Camshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the CMP sensor. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Retainer Torque 8-12 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 1168 Crankshaft Position Sensor: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 1169 The Crankshaft Position Sensor is located at the lower front of engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 1170 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) sensor: - Sends the PCM a signal indicating crankshaft position. - Is essential for calculating spark timing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 1171 Crankshaft Position Sensor: Service and Repair REMOVAL WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 3. Release the tension on the accessory drive belt. 1. Remove the A/C compressor. 1 Remove the A/C compressor bolts. 2 Remove the A/C compressor and position aside. NOTE: Do not remove lines from the A/C compressor. 5. Remove the (A) CKP sensor bolt and the (B) CKP sensor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 1172 To install, reverse the removal procedure NOTE:If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1178 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1179 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1180 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1181 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1182 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Ignition Switch Lock Cylinder: Service and Repair Functional REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key and turn to the RUN position. (2) Press the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. INSTALLATION 1. To install, reverse the removal procedure. - Verify ignition switch lock cylinder operation. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 1185 Ignition Switch Lock Cylinder: Service and Repair Non-Functional REMOVAL 1. Disconnect the battery ground cable. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. 4. Remove the ignition switch lock cylinder. - Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. - Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the bearing and the gear. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 1186 - Thoroughly clean all drill shavings from the steering column and inspect for damage. INSTALLATION 1. To install, reverse the removal procedure, using a new ignition switch lock cylinder. - Verify ignition switch lock cylinder operation. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor 20-27 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 1190 Knock Sensor: Description and Operation The knock sensor is located in the lifter valley and: - Sends a signal to the PCM indicating engine detonation. - If detonation is occurring, the PCM then changes engine timing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 1191 Knock Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the Knock Sensor (KS) . 1 Disconnect the electrical connector. 2 Remove the KS. INSTALLATION 1. Install the Knock Sensor (KS) 1 Install the KS. 2 Connect the electrical connector. 2. Install the intake manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Recalls for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement Technical Service Bulletin # 00B33 Date: 000301 Recall - Airbag Deactivation Shunt Replacement OWNER NOTIFICATION PROGRAM 00B33 Certain Vehicles In Which An Interim Airbag Deactivation Shunt Was Installed By A Ford Or Lincoln Mercury Dealer - Key Activated Airbag "On-Off" Switch Installation ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Refund Codes ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ VIN and Part Number List ^ Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Recalls for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 1201 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Recalls for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 1202 Attachment I - Administrative/Refund Code Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. NOTE: There are 99 vehicles involved in this program nationwide. Deactivation kits are currently available for 57 of these vehicles which are listed in Attachment IV. Only these 57 vehicles, which have an available kit, will be active in OASIS and the owners notified. As new kits become available, OASIS will be updated with new VINs and the owners notified. Consult your Master Parts Catalog for base number 14B385 to determine part numbers for new kits. PROMPTLY CORRECT Promptly correct all affected vehicles on the enclosed list. Please be sure to obtain the customer's authorization to remove the shunt and install the "On-Off" switch. Other eligible vehicles, identified by OASIS, which are brought to your dealership. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII Manual for claims preparation and submission information. RENTAL CARS Rental cars are not approved for this program. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Recalls for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 1203 LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this program. Order your parts requirement through normal order processing channels as noted in the table. PLEASE NOTE: There are 99 vehicles involved nationwide.Of these, 57 have a service part kit available now. Pans kits are in development for the 42 remaining vehicles. Attachment IV contains the VIN and part numbers for the 57 vehicles which have a service pan kit. This is not a list of VINs assigned to your Dealership. Chances are you will not see any of these vehicles. Please do not order parts unless contacted by a customer whose VIN appears in Attachment IV. Do not order for stock. DEALER PRICE For latest prices, check or call your: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information TECHNICAL INSTRUCTIONS: Instructions for removing the airbag shunt and installing the key activated "On-0ff" switch are included in each kit. Please follow the kit instructions carefully when servicing the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Recalls for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 1204 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Recalls for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 1205 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Recalls for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 1206 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Recalls for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 1207 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Recalls for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 1208 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement Technical Service Bulletin # 00B33 Date: 000301 Recall - Airbag Deactivation Shunt Replacement OWNER NOTIFICATION PROGRAM 00B33 Certain Vehicles In Which An Interim Airbag Deactivation Shunt Was Installed By A Ford Or Lincoln Mercury Dealer - Key Activated Airbag "On-Off" Switch Installation ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Refund Codes ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ VIN and Part Number List ^ Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 1214 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 1215 Attachment I - Administrative/Refund Code Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. NOTE: There are 99 vehicles involved in this program nationwide. Deactivation kits are currently available for 57 of these vehicles which are listed in Attachment IV. Only these 57 vehicles, which have an available kit, will be active in OASIS and the owners notified. As new kits become available, OASIS will be updated with new VINs and the owners notified. Consult your Master Parts Catalog for base number 14B385 to determine part numbers for new kits. PROMPTLY CORRECT Promptly correct all affected vehicles on the enclosed list. Please be sure to obtain the customer's authorization to remove the shunt and install the "On-Off" switch. Other eligible vehicles, identified by OASIS, which are brought to your dealership. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII Manual for claims preparation and submission information. RENTAL CARS Rental cars are not approved for this program. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 1216 LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this program. Order your parts requirement through normal order processing channels as noted in the table. PLEASE NOTE: There are 99 vehicles involved nationwide.Of these, 57 have a service part kit available now. Pans kits are in development for the 42 remaining vehicles. Attachment IV contains the VIN and part numbers for the 57 vehicles which have a service pan kit. This is not a list of VINs assigned to your Dealership. Chances are you will not see any of these vehicles. Please do not order parts unless contacted by a customer whose VIN appears in Attachment IV. Do not order for stock. DEALER PRICE For latest prices, check or call your: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information TECHNICAL INSTRUCTIONS: Instructions for removing the airbag shunt and installing the key activated "On-0ff" switch are included in each kit. Please follow the kit instructions carefully when servicing the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 1217 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 1218 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 1219 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 1220 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 1221 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications Impact Sensor: Specifications Air Bag Sensor Screws ........................................................................................................................................................... 10.2-13.8 Nm (91-123 lb in) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Crash Sensor Impact Sensor: Locations Left Crash Sensor Engine View The Left Primary Crash Sensor is located at left front of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Crash Sensor > Page 1227 Impact Sensor: Locations Right Crash Sensor Engine View The Right Primary Crash Sensor is located at right front of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 1228 Impact Sensor: Description and Operation PURPOSE The front air bag sensors are electrical switches that react to frontal impacts according to direction and force. The primary sensors measure the crash severity. OPERATION Primary crash sensors are "hard-wired" to the air bags and operate in the following manner: - They discriminate between impacts that require air bag inflation and impacts that do not. - When an impact occurs that requires air bag inflation, the sensor contacts close, completing the electrical circuit necessary for system operation. - The safing sensor and one primary crash sensor must be activated simultaneously to inflate the air bag. The air bag system is designed to operate in frontal or front-angled collisions. The driver side air bag module and passenger side air bag module should activate in a crash with severe frontal deceleration, more severe than hitting a parked car of similar size and weight head-on at about 45 km/h (28 mph). Because the air bag system senses severity of the crash rather than vehicle speed, some frontal collisions at speeds above 45 km/h (28 mph) may not be severe enough to require air bag inflation. The sensors in the vehicle determine if air bag inflation is required in the following manner: 1. During severe frontal deceleration caused by an impact that decelerates the vehicle in the forward direction, both a radiator primary crash sensor and a safing sensor will activate. 2. When a primary and safing sensor are closed at the same time, electrical current will flow, igniting the driver side air bag module and passenger side air bag module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 1229 Impact Sensor: Service and Repair REMOVAL WARNING: - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag system is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. If damaged, the sensor should be replaced whether or not the air bag is deployed. - Repair is made by replacement only. If a part is replaced and the new part does not correct the condition, install the original part and perform the diagnostic procedure again. - To avoid accidental deployment and possible injury, the backup power supply must be depleted before repairing or replacing any air bag system components. To deplete the backup power supply energy, disconnect the battery to starter relay cable and wait one minute. 1. Disconnect the battery cables. 2. Remove the radiator air deflector. 1 Remove the push clips. 2 Remove the radiator air deflector. 3. Disconnect the air bag sensor electrical connector (RH shown, LH similar). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 1230 4. Remove the air bag sensor. 1 Remove the screws. 2 Remove the air bag sensor. INSTALLATION To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Safing Sensor, Air Bag > Component Information > Locations Safing Sensor: Locations Integral with Air Bag Diagnostic Monitor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Safing Sensor, Air Bag > Component Information > Locations > Page 1234 Safing Sensor: Description and Operation PURPOSE The safing sensor confirms the crash and is used to prevent inadvertent deployments possibly caused by a malfunction in the primary crash sensor circuits or crash sensors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Safing Sensor, Air Bag > Component Information > Locations > Page 1235 Safing Sensor: Service and Repair The safing sensor is internal to the air bag diagnostic module and is not replaced separately. Refer to Air Bag Diagnostic Module / Service and Repair. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1242 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1243 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1244 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1245 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1246 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Ignition Switch Lock Cylinder: Service and Repair Functional REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key and turn to the RUN position. (2) Press the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. INSTALLATION 1. To install, reverse the removal procedure. - Verify ignition switch lock cylinder operation. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 1249 Ignition Switch Lock Cylinder: Service and Repair Non-Functional REMOVAL 1. Disconnect the battery ground cable. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. 4. Remove the ignition switch lock cylinder. - Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. - Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the bearing and the gear. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 1250 - Thoroughly clean all drill shavings from the steering column and inspect for damage. INSTALLATION 1. To install, reverse the removal procedure, using a new ignition switch lock cylinder. - Verify ignition switch lock cylinder operation. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Neutral Safety Switch: Locations Transmission View The Digital Transmission Range Sensor is located at left side of the automatic transmission. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 1254 Digital Transmission Range Sensor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations Steering Angle Sensor: Locations Instrument Panel View The Steering Wheel Rotation Sensor is located behind steering wheel in the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 1260 Steering Angle Sensor: Description and Operation The steering sensor is mounted inside the passenger compartment on the steering column. It provides steering rate and position to the control module through two signals: Steering Sensor A and Steering Sensor B. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Front Ride Height Sensor: Locations Front Body View The Front Height Sensor is located behind left running broad. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Front > Page 1266 Ride Height Sensor: Locations Rear Body View The Rear Height Sensor is located at rear floor panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Description and Operation > Four Wheel Air Suspension Ride Height Sensor: Description and Operation Four Wheel Air Suspension Two height sensors are mounted on the vehicle. The sensors send a voltage signal to the control module. The output ranges from approximately 4.75 volts at minimum height (when the vehicle is low or in full jounce), to 0.25 volts at maximum height (when the vehicle is high or in full rebound). The sensors have a useable range of 80 mm (3 in) compared to total suspension travel of 200-250 mm (8-10 in) at the wheel. Therefore, the sensors are mounted to the suspension at a point where full suspension travel at the wheel is relative to 80 mm (3 in) of travel at the height sensor. The front height sensor upper socket is attached to the bracket to the frame at the upper control arm mounting area and the lower height sensor socket is attached to the upper control arm bracket. The rear height sensor is attached between the No. 5 frame crossmember (upper socket) and the panhard rod (lower socket). Replace a sensor as a unit. When the height sensor gets shorter the vehicle is lowered and this will cause the air compressor to turn on and pump compressed air to the system. When the sensor gets longer the vehicle is being raised and this will cause the air to be vented from the system to lower the vehicle to its trim height level. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Description and Operation > Four Wheel Air Suspension > Page 1269 Ride Height Sensor: Description and Operation Rear Air Suspension When the height sensor gets shorter the rear of the vehicle is lowered and this will cause the air compressor to turn on and pump compressed air to the air springs. When the sensor gets longer the rear of the vehicle is being raised and this will cause the air to be vented from the air springs to lower the vehicle back to its trim height level. One height sensor is mounted on the vehicle. The sensor sends a voltage signal to the control module. The output ranges from approximately 4.75 volts at minimum height (when the vehicle is low or in full jounce), to 0.25 volts at maximum height (when the vehicle is high or in full rebound). The sensor has a useable range of 80 mm (3 in) compared to total suspension travel of 200-250 mm (8 to 10 in) at the wheel. Therefore, the sensor is mounted to the suspension at a point where full rear suspension travel at the wheel is relative to 80 mm of travel at the height sensor. The rear height sensor is attached between the No. 5 frame crossmember (upper socket) and the panhard rod (lower socket). Replace the sensor as a unit. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Adjustments > Inflate and Deflate the Air Suspension System Ride Height Sensor: Adjustments Inflate and Deflate the Air Suspension System 1. Turn the ignition to the run position. WARNING: DO NOT REMOVE AN AIR SPRING UNDER ANY CIRCUMSTANCES WHEN THERE IS PRESSURE IN THE AIR SPRING. DO NOT REMOVE ANY COMPONENTS SUPPORTING AN AIR SPRING WITHOUT EITHER EXHAUSTING THE AIR OR PROVIDING SUPPORT FOR THE AIR SPRING TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. 2. Connect NGS tester to vehicle. 3. Select 1997 4.6L/5.4L Expedition 4WAS module. 4. Select "Air Suspension Control Mode" under "Active Command Modes" menu. (1) Select "VENT REAR" to deflate rear air springs. (2) Select "LIFT REAR" to inflate rear air springs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Adjustments > Inflate and Deflate the Air Suspension System > Page 1272 Ride Height Sensor: Adjustments Rear Height Resetting Procedure 1. Turn ignition key on. 2. Connect NGS tester to the vehicle. 3. Select 1997 4.6L/5.4L Expedition-4WAS module. 4. Measure vehicle rear height (driver side) from the bottom of the frame to the rear jounce bumper bolt rear side of head base. 5. By using NGS tester "active command modes", adjust rear height to 146.8 +/- 2 mm by moving rear of the vehicle down "VENT REAR" or moving rear of the vehicle up "LIFT REAR." 6. Monitor on the right side of the NGS screen rear height sensor voltage. 7. Loosen the ball stud nut on rear height sensor bracket on track bar and adjust by moving with height sensor up or down until rear height sensor voltage is 2.61 +/- 0.03 volt. 8. Tighten nut to specifications. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Adjustments > Page 1273 Ride Height Sensor: Service and Repair REMOVAL 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO S O MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Remove the air suspension height sensor. (1) Disconnect electrical connector. (2) Depress the metal retaining tabs and remove the air suspension height sensor from the ball studs. NOTE: The air suspension height sensor has a plastic harness retainer to suspension that must be unclipped prior to removal. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations Steering Angle Sensor: Locations Instrument Panel View The Steering Wheel Rotation Sensor is located behind steering wheel in the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 1277 Steering Angle Sensor: Description and Operation The steering sensor is mounted inside the passenger compartment on the steering column. It provides steering rate and position to the control module through two signals: Steering Sensor A and Steering Sensor B. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications Suspension Mode Switch: Specifications Switch Bracket Mounting Bolt ........................................................................................................................................... 10.2-13.8 Nm (91-123 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications > Page 1281 Suspension Mode Switch: Description and Operation The air suspension switch is located behind the RH kick panel on a mounting bracket. The switch interrupts power to the control module. The air suspension switch supplies a signal to the control module. Without the control module receiving this signal the load leveling system is inoperative and will not react when rear of the vehicle is raised or lowered. If the air suspension is disabled by turning off air suspension switch, a "CHECK SUSP" will appear in the RH corner of the cluster with the ignition in the run position. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications > Page 1282 Suspension Mode Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front door scuff plate. 3. Remove the cowl side trim panel. 4. Disconnect the air suspension switch electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications > Page 1283 5. Remove the air suspension switch bracket mounting bolt. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > E40D Transmission Transmission Control Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > E40D Transmission > Page 1290 Transmission Control Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Page 1291 Overdrive Switch: Description and Operation The transmission control switch (TCS) is a momentary contact switch. When the switch is pressed, a signal is sent to the powertrain control module (PCM) to allow automatic shifts from first through fourth gears or first through third gears only. The PCM energizes the transmission control indicator lamp (TCIL) when the switch has been pressed to cancel overdrive. The TCIL indicates overdrive cancel mode activated (lamp on) and electronic pressure control (EPC) circuit shorted (lamp flashing) or monitored sensor failure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis Overdrive Switch: Flow of Diagnosis 1. Verify the customer concern by operating the transmission external control. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged shift lock actuator - Damaged transmission control switch - Failed fuse(s) Damaged wiring harness - Loose or corroded connections 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1294 Overdrive Switch: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1295 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1296 Overdrive Switch: Pinpoint Tests Part 1 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1297 Part 2 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1298 Part 3 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1299 Part 4 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1300 Part 5 Of 5 Part 1 Of 3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1301 Part 2 Of 3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1302 Part 3 Of 3 Part 1 Of 4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1303 Part 2 Of 4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1304 Part 3 Of 4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1305 Part 4 Of 4 Part 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1306 Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1307 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Page 1308 Overdrive Switch: Service and Repair REMOVAL 1. Remove the transmission control switch (TCS). (1) Remove the TCS cover. (2) Remove the TCS. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Description and Operation Shift Interlock Switch: Description and Operation The brake shift interlock actuator prevents moving the shift lever out of the PARK position unless the brake pedal is depressed. The actuator receives a signal from the brake on/off (BOO) switch that allows movement of the shift lever. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > New Digital Transmission Range Sensor - Service Tip Transmission Position Switch/Sensor: Technical Service Bulletins New Digital Transmission Range Sensor - Service Tip Article No. 96-24-10 11/18/96 TRANSMISSION - E40D - 4R70W - 4R44E - 5R55E - NEW DIGITAL TRANSMISSION RANGE SENSOR - DIAGNOSIS SERVICE TIP LINCOLN-MERCURY: 1997 MARK VIII LIGHT TRUCK: 1997 AEROSTAR, ECONOLINE, EXPEDITION, EXPLORER, F-150, F-250, MOUNTAINEER ISSUE: Beginning with Job 1 1997, some vehicles will be equipped with a new Digital Transmission Range (DTR) sensor. The DTR sensor is located on the outside of the transmission (Figure 1) at the outer manual lever. ACTION: Refer to the following text to properly diagnose a concern with the DTR sensor. The new DTR sensor completes the start circuit in "Park" and "Neutral," the backup lamp circuit in "Reverse" and the neutral sense circuit (4X4 only) in "Neutral." The DTR sensor also opens/closes a set of four (4) switches that are monitored by the Powertrain Control Module (PCM) to determine the position of the transmission manual lever. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > New Digital Transmission Range Sensor - Service Tip > Page 1316 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > New Digital Transmission Range Sensor - Service Tip > Page 1317 To properly diagnose the DTR sensor, use the NGS, Rotunda Transmission Tester with TR/MLP Cable "E" (Figure 2) and the new DTR Sensor Overlay (Figure 4), while following the procedures outlined in the appropriate model 1997 Service Manual, Section 07-01 or appropriate model 1997 Workshop Manual, Section 307-01. The new DTR Sensor Overlay (007-00131) and updated Tester Manual was sent to all dealers in August 1996. The TR/MLP Cable "E" (007-00111) was sent to all dealers in June 1995 (refer to TSB 95-19-7). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > New Digital Transmission Range Sensor - Service Tip > Page 1318 When using Cable "E" (Figure 3) to diagnose the DTR sensor, the slide switch must be in the "Digital" position and the "Black" 12-pin connector installed on the sensor. Having the slide switch in the incorrect position or using the incorrect 12-pin connector will result in misdiagnosis and possible replacement of a good component. For diagnosis of the DTR sensor, always refer to the appropriate model 1997 Service Manual, Section 07.01 or appropriate model 1997 Workshop Manual, Section 3O7-01 for proper procedure and required equipment. OTHER APPLICABLE ARTICLES: 95-19-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 503000, 503300, 504000, 601300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 1319 Transmission Position Switch/Sensor: Specifications TORQUE SPECIFICATIONS DTR Sensor Bolts ................................................................................................................................ ..................................... 7-10 Nm (62-89 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 1320 Transmission Position Switch/Sensor: Locations Transmission View The Digital Transmission Range Sensor is located at left side of the automatic transmission. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 1321 Digital Transmission Range Sensor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 1322 Transmission Position Switch/Sensor: Adjustments NOTE: Use Digital Transmission Range (DTR) Sensor Alignment Tool to align both TR and DTR sensors. 1. Raise and support vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Disconnect the manual lever shift control cable. 3. Disconnect the TR or DTR electrical connector. 4. Remove the manual control lever. (1) Remove the nut. (2) Remove the lever. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. 5. Loosen the TR or DTR bolts. 6. Use DTR sensor alignment tool, to align the DTR or TR sensor slots. NOTE: Manual shift lever must be in the neutral position. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 1323 7. Tighten the DTR or TR sensor bolts. 8. Install the manual control lever. (1) Position the manual control lever. (2) Install a new manual lever shaft outer nut. 9. With the manual lever in overdrive connect the shift lever control cable. 10. Install the DTR sensor electrical connector. 11. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications TORQUE SPECIFICATIONS Output Shaft Speed (OSS) Sensor Bolt .......................................................................................................................................... 8-16 Nm (6-12 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 1327 Transmission Speed Sensor: Locations Transmission View The Output Shaft Speed Sensor is located at left side of transmission. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 1328 Output Shaft Speed Sensor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Customer Interest: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions Four Wheel Drive Selector Switch: Customer Interest Transfer Case - Multiple Electrical Malfunctions Article No. 01-16-6 08/20/01 ^ LAMP - 4X4 "LOW RANGE" LIGHT DIMLY LIT ^ SWITCHES - TRANSFER CASE MODE SWITCH - 4X4 HI/LOW SWITCH SHORTED OUT ^ WINDSHIELD WIPERS - INTERMITTENT WIPERS ERRATIC OR INOPERABLE ^ TRANSFER CASE - WATER PRESENT IN TRANSFER CASE FORD: 1997 EXPEDITION, F-150, F-250 LD This article is being republished in its entirety to update the labor time. ISSUE Water may be present in the transfer case on some vehicles. This may cause: ^ Transfer Case Mode Switch to become inoperative ^ The 4X4 "Low Range" light to appear dimly lit ^ The intermittent wipers to become erratic or inoperative ^ Vehicle Speed Sensor (VSS) Diagnostic Trouble Codes (DTCs) P0500, P0503, P1500, and P1501 to be set. This may be caused by water splashing into the transfer case through the vent tube assembly, possibly causing the transfer case mode switch to short out, and/or the VSS gear to swell and set the VSS DTCs listed above. Shorting out the transfer case mode switch may cause the intermittent wiper mode to function erratically, as well as possibly causing the 4X4 light to work incorrectly. ACTION Inspect, diagnose, and/or replace the necessary components. Refer to the following Service Procedure for details. SERVICE PROCEDURE Procedure for VSS Gear: 1. Inspect VSS gear in the transfer case for looseness. 2. Replace Gear (C80Z-17285-B) as necessary. Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Mode Switch: 1. Check resistance of the Transfer Case Mode Switch. 2. The resistance of the switch should be at least 100,000 ohms. If it is less, replace the switch (3-Position Switch, E7TZ-7E440-A, manual shift only). Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Vent Replacement: 1. Remove old vent hose from fitting on front of transfer case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Customer Interest: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 1338 2. Attach end of new Vent Hose (F75Z-7A246-M) to fitting, and route the hose up over the top of the transfer case (Figure 1). 3. Attach the clip on the vent hose to the top of the vertical rib on the transfer case extension housing to support the end of the hose (Figure 2). NOTE FOR ALL WATER CONCERNS, DRAIN AND REFILL THE TRANSFER CASE WITH FRESH FLUID (XT-2-QDX), AND REPLACE THE VENT HOSE WITH THE REVISED PART. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Customer Interest: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 1339 SUPERSEDES:97-11-19 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011606A Drain And Refill Transfer 1.2 Hrs. Case, Inspect And/Or Replace VSS Gear And Transfer Case Mode Switch, And Install Vent Kit DEALER CODING CONDITION BASIC PART NO. CODE 7D494 49 OASIS CODES: 202000, 206000, 508000, 508300, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions Four Wheel Drive Selector Switch: All Technical Service Bulletins Transfer Case - Multiple Electrical Malfunctions Article No. 01-16-6 08/20/01 ^ LAMP - 4X4 "LOW RANGE" LIGHT DIMLY LIT ^ SWITCHES - TRANSFER CASE MODE SWITCH - 4X4 HI/LOW SWITCH SHORTED OUT ^ WINDSHIELD WIPERS - INTERMITTENT WIPERS ERRATIC OR INOPERABLE ^ TRANSFER CASE - WATER PRESENT IN TRANSFER CASE FORD: 1997 EXPEDITION, F-150, F-250 LD This article is being republished in its entirety to update the labor time. ISSUE Water may be present in the transfer case on some vehicles. This may cause: ^ Transfer Case Mode Switch to become inoperative ^ The 4X4 "Low Range" light to appear dimly lit ^ The intermittent wipers to become erratic or inoperative ^ Vehicle Speed Sensor (VSS) Diagnostic Trouble Codes (DTCs) P0500, P0503, P1500, and P1501 to be set. This may be caused by water splashing into the transfer case through the vent tube assembly, possibly causing the transfer case mode switch to short out, and/or the VSS gear to swell and set the VSS DTCs listed above. Shorting out the transfer case mode switch may cause the intermittent wiper mode to function erratically, as well as possibly causing the 4X4 light to work incorrectly. ACTION Inspect, diagnose, and/or replace the necessary components. Refer to the following Service Procedure for details. SERVICE PROCEDURE Procedure for VSS Gear: 1. Inspect VSS gear in the transfer case for looseness. 2. Replace Gear (C80Z-17285-B) as necessary. Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Mode Switch: 1. Check resistance of the Transfer Case Mode Switch. 2. The resistance of the switch should be at least 100,000 ohms. If it is less, replace the switch (3-Position Switch, E7TZ-7E440-A, manual shift only). Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Vent Replacement: 1. Remove old vent hose from fitting on front of transfer case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 1345 2. Attach end of new Vent Hose (F75Z-7A246-M) to fitting, and route the hose up over the top of the transfer case (Figure 1). 3. Attach the clip on the vent hose to the top of the vertical rib on the transfer case extension housing to support the end of the hose (Figure 2). NOTE FOR ALL WATER CONCERNS, DRAIN AND REFILL THE TRANSFER CASE WITH FRESH FLUID (XT-2-QDX), AND REPLACE THE VENT HOSE WITH THE REVISED PART. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 1346 SUPERSEDES:97-11-19 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011606A Drain And Refill Transfer 1.2 Hrs. Case, Inspect And/Or Replace VSS Gear And Transfer Case Mode Switch, And Install Vent Kit DEALER CODING CONDITION BASIC PART NO. CODE 7D494 49 OASIS CODES: 202000, 206000, 508000, 508300, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Four Wheel Drive Selector Switch: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Cruise Control Switch: All Technical Service Bulletins Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Page 1357 Four Wheel Drive Selector Switch: Specifications TORQUE SPECIFICATIONS Shift Range Selector Switch Screws ........................................................................................................................................... 2-3 Nm (18-26 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Page 1358 4 Wheel Drive Mode Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Page 1359 Four Wheel Drive Selector Switch: Description and Operation The 4WD mode switch is a rotary switch which allows the vehicle operator to choose between 2WD, A4WD, 4WD HIGH, and LOW range positions. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Page 1360 Four Wheel Drive Selector Switch: Service and Repair REMOVAL 1. Remove the center instrument panel trim plate. 2. Remove the shift range selector switch. (1) Remove the shift range selector switch knob. (2) Disconnect the shift range selector switch electrical connector. (3) Remove the two shift range selector switch screws. (4) Remove the shift range selector switch. INSTALLATION 1. Install the shift range selector switch. (1) Position the shift range selector switch. (2) Install the bolts. (3) Install the electrical connectors. (4) Install the knob. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Page 1361 2. Install the center instrument panel trim panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Speed Sensor: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions Speed Sensor: Customer Interest Transfer Case - Multiple Electrical Malfunctions Article No. 01-16-6 08/20/01 ^ LAMP - 4X4 "LOW RANGE" LIGHT DIMLY LIT ^ SWITCHES - TRANSFER CASE MODE SWITCH - 4X4 HI/LOW SWITCH SHORTED OUT ^ WINDSHIELD WIPERS - INTERMITTENT WIPERS ERRATIC OR INOPERABLE ^ TRANSFER CASE - WATER PRESENT IN TRANSFER CASE FORD: 1997 EXPEDITION, F-150, F-250 LD This article is being republished in its entirety to update the labor time. ISSUE Water may be present in the transfer case on some vehicles. This may cause: ^ Transfer Case Mode Switch to become inoperative ^ The 4X4 "Low Range" light to appear dimly lit ^ The intermittent wipers to become erratic or inoperative ^ Vehicle Speed Sensor (VSS) Diagnostic Trouble Codes (DTCs) P0500, P0503, P1500, and P1501 to be set. This may be caused by water splashing into the transfer case through the vent tube assembly, possibly causing the transfer case mode switch to short out, and/or the VSS gear to swell and set the VSS DTCs listed above. Shorting out the transfer case mode switch may cause the intermittent wiper mode to function erratically, as well as possibly causing the 4X4 light to work incorrectly. ACTION Inspect, diagnose, and/or replace the necessary components. Refer to the following Service Procedure for details. SERVICE PROCEDURE Procedure for VSS Gear: 1. Inspect VSS gear in the transfer case for looseness. 2. Replace Gear (C80Z-17285-B) as necessary. Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Mode Switch: 1. Check resistance of the Transfer Case Mode Switch. 2. The resistance of the switch should be at least 100,000 ohms. If it is less, replace the switch (3-Position Switch, E7TZ-7E440-A, manual shift only). Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Vent Replacement: 1. Remove old vent hose from fitting on front of transfer case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Speed Sensor: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 1370 2. Attach end of new Vent Hose (F75Z-7A246-M) to fitting, and route the hose up over the top of the transfer case (Figure 1). 3. Attach the clip on the vent hose to the top of the vertical rib on the transfer case extension housing to support the end of the hose (Figure 2). NOTE FOR ALL WATER CONCERNS, DRAIN AND REFILL THE TRANSFER CASE WITH FRESH FLUID (XT-2-QDX), AND REPLACE THE VENT HOSE WITH THE REVISED PART. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Speed Sensor: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 1371 SUPERSEDES:97-11-19 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011606A Drain And Refill Transfer 1.2 Hrs. Case, Inspect And/Or Replace VSS Gear And Transfer Case Mode Switch, And Install Vent Kit DEALER CODING CONDITION BASIC PART NO. CODE 7D494 49 OASIS CODES: 202000, 206000, 508000, 508300, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions Speed Sensor: All Technical Service Bulletins Transfer Case - Multiple Electrical Malfunctions Article No. 01-16-6 08/20/01 ^ LAMP - 4X4 "LOW RANGE" LIGHT DIMLY LIT ^ SWITCHES - TRANSFER CASE MODE SWITCH - 4X4 HI/LOW SWITCH SHORTED OUT ^ WINDSHIELD WIPERS - INTERMITTENT WIPERS ERRATIC OR INOPERABLE ^ TRANSFER CASE - WATER PRESENT IN TRANSFER CASE FORD: 1997 EXPEDITION, F-150, F-250 LD This article is being republished in its entirety to update the labor time. ISSUE Water may be present in the transfer case on some vehicles. This may cause: ^ Transfer Case Mode Switch to become inoperative ^ The 4X4 "Low Range" light to appear dimly lit ^ The intermittent wipers to become erratic or inoperative ^ Vehicle Speed Sensor (VSS) Diagnostic Trouble Codes (DTCs) P0500, P0503, P1500, and P1501 to be set. This may be caused by water splashing into the transfer case through the vent tube assembly, possibly causing the transfer case mode switch to short out, and/or the VSS gear to swell and set the VSS DTCs listed above. Shorting out the transfer case mode switch may cause the intermittent wiper mode to function erratically, as well as possibly causing the 4X4 light to work incorrectly. ACTION Inspect, diagnose, and/or replace the necessary components. Refer to the following Service Procedure for details. SERVICE PROCEDURE Procedure for VSS Gear: 1. Inspect VSS gear in the transfer case for looseness. 2. Replace Gear (C80Z-17285-B) as necessary. Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Mode Switch: 1. Check resistance of the Transfer Case Mode Switch. 2. The resistance of the switch should be at least 100,000 ohms. If it is less, replace the switch (3-Position Switch, E7TZ-7E440-A, manual shift only). Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Vent Replacement: 1. Remove old vent hose from fitting on front of transfer case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 1377 2. Attach end of new Vent Hose (F75Z-7A246-M) to fitting, and route the hose up over the top of the transfer case (Figure 1). 3. Attach the clip on the vent hose to the top of the vertical rib on the transfer case extension housing to support the end of the hose (Figure 2). NOTE FOR ALL WATER CONCERNS, DRAIN AND REFILL THE TRANSFER CASE WITH FRESH FLUID (XT-2-QDX), AND REPLACE THE VENT HOSE WITH THE REVISED PART. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 1378 SUPERSEDES:97-11-19 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011606A Drain And Refill Transfer 1.2 Hrs. Case, Inspect And/Or Replace VSS Gear And Transfer Case Mode Switch, And Install Vent Kit DEALER CODING CONDITION BASIC PART NO. CODE 7D494 49 OASIS CODES: 202000, 206000, 508000, 508300, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Page 1379 Speed Sensor: Specifications TORQUE SPECIFICATIONS Output Speed Sensor Bolt ........................................................................................................................................................... 3-6 Nm (27-53 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams Rear Heated Window Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Driver's Power Window Switch Power Window Switch: Diagrams Driver's Power Window Switch Left Front Power Window Switch (C510) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Driver's Power Window Switch > Page 1388 Left Front Power Window Switch (C509) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Driver's Power Window Switch > Page 1389 Power Window Switch: Diagrams Rear Power Window Switch Left Rear Window Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Driver's Power Window Switch > Page 1390 Right Rear Window Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Driver's Power Window Switch > Page 1391 Right Front Power Window Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Driver's Power Window Switch > Page 1392 Power Window Switch: Diagrams Vent Window Switch Left Rear Vent Window Switch Right Rear Vent Window Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation > Window Regulator Control Quarter Window Switch (Optional) Power Window Switch: Description and Operation Window Regulator Control Quarter Window Switch (Optional) The quarter window regulator control switches: - Are located in the center roof console. - May be used to open and close RH or LH rear quarter windows. - Stop the rear quarter windows in any position when released. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation > Window Regulator Control Quarter Window Switch (Optional) > Page 1395 Power Window Switch: Description and Operation Window Regulator Control Switch The window regulator control switch: - Is located on each front door trim panel. - May be used to raise or lower all windows from the master control on the driver side, or the individual side window from the individual door switch. - Includes a "double detent" feature. - Can manually lower the driver side window when the master control is depressed half way (first detent). - Will completely lower the driver side window when the master control is fully depressed and then released (second detent). - Can lock out passenger front and rear control switches. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications Windshield Washer Switch: Specifications TORQUE SPECIFICATIONS Multi-Function Switch Screws .................................................................................................................................................... 3-5 Nm (18-26 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 1400 Windshield Washer Switch: Diagrams Multi-Function Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 1401 Multi-Function Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 1402 Windshield Washer Switch: Description and Operation The Multi-function switch is mounted to the LH side of the steering column and controls the: ^ Turn signal. ^ Hazard flasher. ^ Windshield wiper/washer. ^ Rear wiper/washer. ^ Headlamp dimmer/flash-to-pass. ^ Ignition. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis Windshield Washer Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: ^ Damaged multi-function switch ^ Blown fuse(s) ^ Damaged ignition switch ^ Damaged wiring harness ^ Loose or corroded 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1405 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1406 Windshield Washer Switch: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1407 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1408 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1409 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1410 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1411 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1412 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1413 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1414 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1415 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1416 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1417 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1418 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 1419 Windshield Washer Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Push the (A) ignition switch lock cylinder release tab with a punch while pulling out the (B) ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank and remove. 4. Release the (A) four clips and remove the (B) steering column opening cover. 5. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 1420 (3) Remove the upper steering column shroud. 6. Remove the multi-function switch. (1) Remove the two screws. (2) Disconnect the electrical connectors. (3) Remove the multi-function switch. NOTE: The steering wheel has been removed for clarity. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Specifications Wiper Switch: Specifications TORQUE SPECIFICATIONS Multi-Function Switch Screws .................................................................................................................................................... 3-5 Nm (18-26 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Specifications > Page 1424 Wiper Switch: Diagrams Multi-Function Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Specifications > Page 1425 Multi-Function Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Specifications > Page 1426 Wiper Switch: Description and Operation The Multi-function switch is mounted to the LH side of the steering column and controls the: ^ Turn signal. ^ Hazard flasher. ^ Windshield wiper/washer. ^ Rear wiper/washer. ^ Headlamp dimmer/flash-to-pass. ^ Ignition. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis Wiper Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: ^ Damaged multi-function switch ^ Blown fuse(s) ^ Damaged ignition switch ^ Damaged wiring harness ^ Loose or corroded 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1429 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1430 Wiper Switch: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1431 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1432 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1433 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1434 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1435 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1436 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1437 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1438 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1439 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1440 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1441 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1442 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 1443 Wiper Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Push the (A) ignition switch lock cylinder release tab with a punch while pulling out the (B) ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank and remove. 4. Release the (A) four clips and remove the (B) steering column opening cover. 5. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 1444 (3) Remove the upper steering column shroud. 6. Remove the multi-function switch. (1) Remove the two screws. (2) Disconnect the electrical connectors. (3) Remove the multi-function switch. NOTE: The steering wheel has been removed for clarity. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1450 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1451 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1452 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1453 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1454 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1455 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1456 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1457 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1458 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1459 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1460 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1461 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1462 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1463 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1464 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1465 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1466 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1467 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1468 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1469 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1470 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1471 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1472 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1473 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1474 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1475 Ford Expedition 4wd Workshop Manual 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Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1480 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1481 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1482 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1483 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1484 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1485 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1486 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1487 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1488 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1489 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1490 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1491 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1492 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1493 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1494 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1495 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1496 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1497 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1498 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1499 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1500 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1501 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1502 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1503 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1504 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1505 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1506 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1507 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1508 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1509 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1510 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1511 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1512 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1513 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1514 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1515 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1516 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1517 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1518 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1519 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1520 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1521 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1522 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1523 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1524 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1525 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1526 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1527 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1528 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1529 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1530 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1531 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1532 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1533 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1534 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1535 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1536 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1537 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1538 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1539 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1540 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1541 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1542 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1543 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1544 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1545 Alignment: Technical Service Bulletins Alignment - Toe Setting Procedure Tip Article No. 98-16-9 08/17/98 STEERING - ALIGNMENT - TOE SET PROCEDURE - SERVICE TIP LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250, NAVIGATOR ISSUE It may be difficult to set toe with the jam nut tie rod sleeve while performing an alignment on some vehicles. This may be caused by the toe adjusting sleeve moving when the opposing jam nut is torqued. ACTION Refer to the following Service Procedure to ensure complete and accurate toe set/alignment by preventing the jam nut from backing off during the toe set procedure. SERVICE PROCEDURE When adjusting toe on 1997-98 F-150/F-250, Expedition, or Navigator, follow this procedure on each side of the vehicle when tightening the jam nuts. 1. Set toe to specification. 2. Make sure the inner and outer ball joint sockets are centered perpendicular to their studs. 3. Prevent the adjuster sleeve from rotating by securing it with a tool (pipe wrench or vise grip) against the lower control arm. 4. Torque one (1) jam nut to 90 Nm (66 lb-ft). 5. Paint a line across the adjuster sleeve and the torqued jam nut and another line across the torqued jam nut and tie rod threads. 6. With the wrench still preventing the adjuster sleeve from rotating, torque the other jam nut to 90 Nm (66 lb-ft). 7. Inspect the paint lines to be sure no relative movement of the adjuster sleeve, jam nut, or tie rod occurred. 8. If movement is detected or toe is no longer within specification, loosen both jam nuts, reset toe if necessary, and repeat procedure. 9. Repeat procedure for other side of vehicle. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 303000, 390000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Base Suspension Alignment: Specifications Base Suspension CASTER LH ........................................................................................................................................................ ................................ (+4.8° ± 1.0°) +3.8° to +5.8° RH ......................................................................... ............................................................................................................... (+5.2° ± 1.0°) +4.2° to +6.2° Total/Split ............................................................................................................................................. .......................... (-0.4° split ± 0.7°) -1.1° to +0.3° CAMBER LH ........................................................................................................................................................ ................................... (-0.1— ± 0.7°) -0.8 to +0.6 RH ........................................................................ ................................................................................................................... (-0.1— ± 0.7°) -0.8 to +0.6 Total/Split .................................................................................................................................... .................................... (0.0° split ± 0.7°) -0.7° to +0.7° TOE LH ........................................................................................................................................................ ...................................................................... 0.10° RH ....................................................................... ...................................................................................................................................................... 0.10° Total/Split .......................................................................................................................................................... (+0.20° Toe-in ± 0.25°) -0.05° to +0.45° RIDE HEIGHT Ride Height w/ Base Suspension Measurement - Original Components ........................................................................................................................ 104-134 mm (4.09-5.28 inches) Reset - Original Components ..................................................................................................................................... 109-115 mm (4.29-4.53 inches) Reset - New Components ........................................................................................................................................... 123-129 mm (4.84-5.08 inches) Rear Curb Ride Height Specifications: Without Air Suspension ................................................................................................................................................. 150-205 mm (5.9-8.1 inches) Vehicle Lean Specifications Maximum allowable variance: Front .................................................................................................................................................... ....................................... 16 mm (5/8 inch) Rear ................................................................................. ........................................................................................................... 19 mm (3/4 inch) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Base Suspension > Page 1548 Alignment: Specifications W/ Air Suspension CASTER LH ........................................................................................................................................................ ................................ (+6.8° ± 1.0°) +5.8° to +7.8° RH ......................................................................... ............................................................................................................... (+7.3° ± 1.0°) +6.3° to +8.3° Total/Split ............................................................................................................................................. .......................... (-2.5° split ± 0.7°) -3.2° to -1.8° CAMBER LH ........................................................................................................................................................ .................................. (-0.3° ± 0.7°) -1.0° to +0.4° RH ......................................................................... ................................................................................................................. (-0.3° ± 0.7°) -1.0° to +0.4° Total/Split ............................................................................................................................................. ........................... (0.0° split ± 0.7°) -0.7° to +0.7° TOE LH ........................................................................................................................................................ ...................................................................... 0.05° RH ....................................................................... ...................................................................................................................................................... 0.03° Total/Split .......................................................................................................................................................... (+0.06° Toe-in ± 0.25°) -0.19° to +0.31° RIDE HEIGHT Ride Height w/ Air Suspension - Ignition Off (Kneel Position) Measurement - Original Components ............................................................................................................................ 62-88 mm (2.44-3.46 inches) Reset - Original Components ......................................................................................................................................... 77-83 mm (3.03-3.27 inches) Reset - New Components ............................................................................................................................................... 77-83 mm (3.03-3.27 inches) Rear Curb Ride Height Specifications: With Air Suspension .............................................................................................................................................. 144.8-148.8 mm (5.7-5.85 inches) Vehicle Lean Specifications Maximum allowable variance: Front .................................................................................................................................................... ....................................... 16 mm (5/8 inch) Rear ................................................................................. ........................................................................................................... 19 mm (3/4 inch) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1549 Alignment: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1550 Alignment: Description and Operation DESCRIPTION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1551 Caster and camber are adjusted by means of eccentric cams on the upper control arm mounting bolts. Toe is adjusted by the use of the front wheel spindle tie rod adjusting sleeve. The three basic alignment angles are camber, caster and toe. Camber and toe affect tire wear and directional stability, caster affects directional stability only. Camber, caster and toe settings change when the vehicle is loaded. The specifications given in this section are static settings with the vehicle unloaded. CAMBER Camber is the inward or outward tilting of the wheels at the top. When the wheels tilt out at the top the camber is positive (+). When the wheels tilt in at the top the camber is negative (-). The amount of camber is measured in degrees from vertical. Steering axis inclination (included angle) is the center line drawn through the ball joints when viewed from the front. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1552 CASTER Caster is the tilting of the steering axis either forward or backward from vertical. A backward tilt is positive (+) and a forward tilt is negative (-). TOE Toe is a measurement of how much the front of the wheels are turned in or out from the straight-ahead position. When the wheels are turned in, toe is positive (+)(toe in). When the wheels are turned out, toe is negative (-)(toe out). Toe is measured in degrees, from side to side and totaled. Toe should only be checked and adjusted after the camber and caster have been set to the proper specifications. Wheel Track Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1553 WHEEL TRACK By design the vehicle has a front track that is wider at the front than the rear. Front track is the distance between the two front tires; rear track is the distance between the two rear tires. Dogtracking DOGTRACKING Dogtracking is the condition where the rear axle is not square to the chassis. Heavily crowned roads may give the illusion of dogtracking. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Caster and Camber Alignment: Service and Repair Caster and Camber 1. Loosen the upper suspension arm cam nuts. 2. To increase caster, move the (A) front of the front suspension upper arm outboard and move the (B) rear of the front suspension upper arm inboard. To increase camber, move the (C) front suspension upper arm outboard equally. 3. To decrease caster, move the (A) front of the front suspension upper arm inboard and move the (B) rear of the front suspension upper arm outboard. To decrease camber, move the (C) front suspension upper arm inboard equally. 4. Tighten the upper suspension arm cam nuts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Caster and Camber > Page 1556 Alignment: Service and Repair Toe 1. Start the engine and center the steering wheel. 2. Turn the engine off, and hold the steering wheel in the "straight forward" position by attaching, a rigid link from the steering wheel to the brake pedal. 3. Check the toe settings; follow manufacturer's instructions. 4. Hold the (A) tie rod end while loosening the (B) toe set jam nuts. 5. Rotate the (A) front wheel spindle tie rod adjusting sleeve to desired position. 6. Tighten the toe set jam nuts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Caster and Camber > Page 1557 NOTE: Whenever the toe set jam nuts are loosened for toe adjustment, the nut and tie rod threads must be cleaned and lubricated. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications Fuel Pressure Test Port: Specifications Pressure Relief Valve 7.75 Nm Pressure Relief Valve Cap 0.6 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 1563 Fuel Pressure Test Port: Locations Typical Location The fuel pressure test point/port is a Schrader fitting, located in the fuel rail. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 1564 Fuel Pressure Test Port: Service Precautions WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited, resulting in possible injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. - Before repairing or disconnecting any of the fuel lines or fuel system components, the fuel system fuel pressure release procedure must be performed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 1565 Fuel Pressure Test Port: Description and Operation Typical Location Purpose There is a pressure test point with a Schrader fitting in the fuel rail, which is used for fuel pressure release and to measure the injector supply pressure for service and diagnostic work. NOTE:Before servicing or testing the fuel system, read CAUTION, WARNING, and HANDLING information. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 1566 Fuel Pressure Test Port: Service and Repair REMOVAL 1. Perform Fuel Pressure Release Procedure 2. Remove the fuel pressure relief valve. INSTALLATION To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > System Diagnosis Air/Fuel Mixture: Testing and Inspection To avoid potential misdiagnosis and the unnecessary replacement of components, it is recommended that diagnosis and testing begin with Diagnostic Routines (Diagnosis by Symptom) at the Powertrain Management level. The Diagnostic Routines will lead the technician through the logical and methodical testing of a "specific" subsystem and it's related wiring and components. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > System Diagnosis > Page 1570 Air/Fuel Mixture: Adjustments Air Fuel Ratio is NOT adjustable. If a problem exists, or is suspected, go to the Diagnostic Charts: See Powertrain Management Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Idle Speed (Non-Adjustable) Idle Speed (Non-Adjustable) Base Idle Speed (Standard Trans/Hot) 750 +/- 25 rpm Base Idle Speed (Automatic Trans/Hot) 824 +/- 25 rpm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1574 Idle Speed: Adjustments Engine Idle RPM is controlled by the PCM and is NOT adjustable. If a problem exists, or is suspected, see: Powertrain Management / Symptom Charts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Tube Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Outlet Tube REMOVAL 1. Remove the accelerator control splash shield. 1 Remove the accelerator control splash shield bolts. 2 Remove the accelerator control splash shield. 2. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 3. Disconnect the (A) positive crankcase ventilation hose and the (B) idle air control valve inlet tube. 4. Loosen the two air cleaner outlet tube hose clamp screws and remove the air cleaner outlet tube. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Tube > Page 1580 To install, reverse the removal procedure. CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Tube > Page 1581 Air Cleaner Fresh Air Duct/Hose: Service and Repair Removal and Installation REMOVAL 1. Open the (A) air cleaner clamp and set the (B) outlet engine air cleaner aside. 2. Lift the (B) open end of the (A) inlet engine air cleaner until free of the (C) engine air cleaner support insulators. CAUTION: The inlet engine air cleaner should be removed as an assembly. Do not separate the air cleaner from the fender inlet tube during removal or installation. 3. Pull the inlet engine air cleaner away from the inner fender. INSTALLATION CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. NOTE: The inlet engine air cleaner has an alignment tab which fits into a slot on the outlet engine air cleaner. This ensures a good seal and keeps unmetered air from entering the engine. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL 1. Open the (A) air cleaner clamp and set the (B) outlet engine air cleaner aside. 2. Remove the (A) air cleaner element from the (B) open end of the inlet engine air cleaner. INSTALLATION 1. Install the air cleaner element. NOTE: The inlet engine air cleaner has an alignment tab which fits into a slot on the outlet engine air cleaner. This ensures a good seal and keeps unmetered air from entering the engine. CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. 2. Position the engine air cleaner aligning the alignment tab. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1585 3. Close the air cleaner clamp. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Locations Fuel Pressure Release: Locations Fuel Pressure Port (Typical) A fuel system service port is provided on the fuel rail. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Locations > Page 1590 Fuel Pressure Release: Service Precautions WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited, resulting in possible injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. - Before repairing or disconnecting any of the fuel lines or fuel system components, the fuel system fuel pressure release procedure must be performed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Locations > Page 1591 Fuel Pressure Release: Service and Repair Fuel Pressure Port (Typical) 1. Remove the schrader valve cap and attach EFI/CFI Fuel Pressure Gauge. 2. Open the manual valve on EFI/CFI Fuel Pressure Gauge and Perform Fuel Pressure Release. NOTE: Open manual value slowly to relieve system pressure. - This will drain some fuel out of the system. - Place fuel in suitable a container. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications The RH (Passenger's) side ................................................................................................................. ................................................ Cylinders 1, 2, 3, and 4 The LH (Driver's side) .......................................................................................................................... ............................................. Cylinders 5, 6, 7 and 8 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 1595 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 1596 Firing Order 1-3-7-2-6-5-4-8 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Firing Order Firing Order: 1-3-7-2-6-5-4-8 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Locations Timing Marks and Indicators: Locations The timing marks are located on the crankshaft pulley/damper. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Secondary Suppression Resistor, Ignition > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 962523 > Dec > 96 > Spark Plug Wires MIL ON/DTCs P0300 Through P0308 Set Spark Plug: Customer Interest Spark Plug Wires - MIL ON/DTCs P0300 Through P0308 Set Article No. 96-25-23 12/02/96 ^ RUNS ROUGH - MALFUNCTION INDICATOR LAMP (MIL) ON-DIAGNOSTIC TROUBLE CODES (DTCS) P0300 THROUGH P0308 STORED IN MEMORY - VEHICLES BUILT THROUGH 10/14/96 WITH 4.6L ENGINE ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ON - RUNS ROUGH - DIAGNOSTIC TROUBLE CODES (DTCS) P0300 THROUGH P0308 STORED IN MEMORY - VEHICLES BUILT THROUGH 10/14/96 WITH 4.6L ENGINE LIGHT TRUCK: 1997 ECONOLINE, EXPEDITION, F-150 ISSUE: The Malfunction Indicator Lamp (MIL) may illuminate and Diagnostic Trouble Codes (DTCs) P0300 through P0308 may be stored in memory and/or the engine may run rough. This may be caused by water intrusion into the spark plug well causing the spark to travel directly to ground instead of through the spark plug, resulting in a misfire. ACTION: Inspect the spark plugs for signs of moisture and replace the spark plugs and spark plug wires. Apply dielectric compound on all of the spark plug wire boots. The new spark plug wires and the dielectric compound should reduce the possibility of misfire if water intrusion into the spark plug well occurs. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect and remove any water that may be sitting in the spark plug wells by blowing out the water using compressed air. 2. Inspect the spark plugs for signs of "tracking." If "tracking" is present, there may be a fine, broken "pencil" line on the blue rings only and/or a thick smudgy series of continuous lines depending on how long the vehicle was operated while misfiring. These lines may feel like a crack if the fingernail is rubbed across the lines. Refer to Figure 1. 3. If "tracking" is found, replace all eight (8) of the spark plugs and torque the new Spark Plugs (AWSF-32-PP) to 16-20 N.m (12-15 lb-ft). 4. Replace all eight (8) of the Spark Plug Wires with new wires (F6PZ-12259-HC). Be sure to apply Silicone Caliper Grease and Dielectric Compound (D7AZ-19A331-A) on the inside of all spark plug wire boots. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 962523 > Dec > 96 > Spark Plug Wires MIL ON/DTCs P0300 Through P0308 Set > Page 1616 5. Position the spark plug wire boots 90 degrees to the crankshaft centerline with the spark plug wires facing outboard. The lip of the spark plug wire boot must be flush to the manifold. Refer to Figure 2. PART NUMBER PART NAME F6PZ-12259-HC Spark Plug Wires AWSF-32-PP Spark Plug D7AZ-19A331-A Silicone caliper Grease And Dielectric Compound OTHER APPLICABLE ARTICLES: 96-20-5 960923 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 962523 > Dec > 96 > Spark Plug Wires MIL ON/DTCs P0300 Through P0308 Set > Page 1617 OPERATION DESCRIPTION TIME 962523A Replace Spark Plugs And 1.1 Hr. Wires DEALER CODING CONDITION BASIC PART NO. CODE 12286 48 OASIS CODES: 206000, 608400, 608500, 608600, 609000, 609400, 609500, 609600, 609800, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 962523 > Dec > 96 > Spark Plug Wires - MIL ON/DTCs P0300 Through P0308 Set Spark Plug: All Technical Service Bulletins Spark Plug Wires - MIL ON/DTCs P0300 Through P0308 Set Article No. 96-25-23 12/02/96 ^ RUNS ROUGH - MALFUNCTION INDICATOR LAMP (MIL) ON-DIAGNOSTIC TROUBLE CODES (DTCS) P0300 THROUGH P0308 STORED IN MEMORY - VEHICLES BUILT THROUGH 10/14/96 WITH 4.6L ENGINE ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ON - RUNS ROUGH - DIAGNOSTIC TROUBLE CODES (DTCS) P0300 THROUGH P0308 STORED IN MEMORY - VEHICLES BUILT THROUGH 10/14/96 WITH 4.6L ENGINE LIGHT TRUCK: 1997 ECONOLINE, EXPEDITION, F-150 ISSUE: The Malfunction Indicator Lamp (MIL) may illuminate and Diagnostic Trouble Codes (DTCs) P0300 through P0308 may be stored in memory and/or the engine may run rough. This may be caused by water intrusion into the spark plug well causing the spark to travel directly to ground instead of through the spark plug, resulting in a misfire. ACTION: Inspect the spark plugs for signs of moisture and replace the spark plugs and spark plug wires. Apply dielectric compound on all of the spark plug wire boots. The new spark plug wires and the dielectric compound should reduce the possibility of misfire if water intrusion into the spark plug well occurs. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect and remove any water that may be sitting in the spark plug wells by blowing out the water using compressed air. 2. Inspect the spark plugs for signs of "tracking." If "tracking" is present, there may be a fine, broken "pencil" line on the blue rings only and/or a thick smudgy series of continuous lines depending on how long the vehicle was operated while misfiring. These lines may feel like a crack if the fingernail is rubbed across the lines. Refer to Figure 1. 3. If "tracking" is found, replace all eight (8) of the spark plugs and torque the new Spark Plugs (AWSF-32-PP) to 16-20 N.m (12-15 lb-ft). 4. Replace all eight (8) of the Spark Plug Wires with new wires (F6PZ-12259-HC). Be sure to apply Silicone Caliper Grease and Dielectric Compound (D7AZ-19A331-A) on the inside of all spark plug wire boots. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 962523 > Dec > 96 > Spark Plug Wires - MIL ON/DTCs P0300 Through P0308 Set > Page 1623 5. Position the spark plug wire boots 90 degrees to the crankshaft centerline with the spark plug wires facing outboard. The lip of the spark plug wire boot must be flush to the manifold. Refer to Figure 2. PART NUMBER PART NAME F6PZ-12259-HC Spark Plug Wires AWSF-32-PP Spark Plug D7AZ-19A331-A Silicone caliper Grease And Dielectric Compound OTHER APPLICABLE ARTICLES: 96-20-5 960923 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 962523 > Dec > 96 > Spark Plug Wires - MIL ON/DTCs P0300 Through P0308 Set > Page 1624 OPERATION DESCRIPTION TIME 962523A Replace Spark Plugs And 1.1 Hr. Wires DEALER CODING CONDITION BASIC PART NO. CODE 12286 48 OASIS CODES: 206000, 608400, 608500, 608600, 609000, 609400, 609500, 609600, 609800, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Electrode Gap 1.32-1.42 mm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 1627 Spark Plug: Specifications Spark Plug 9-20 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1628 Spark Plug: Locations The Spark Plugs are located along the inboard sides of the cylinder heads, and outboard of the intake manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1629 Spark Plug: Application and ID RH Original Spark Plug ....................................................................................................................... ........................................................ AWSF32PG (a) LH Original Spark Plug ..................................... ............................................................................................................................................. AWSF32P (a) Replacement Spark Plug (Either Side) ......................................................................................................................................................... AWSF32PP (a) (a) If a spark plug is removed for examination, it must be reinstalled in the same cylinder. If a spark plug needs to be replaced, use only spark plugs with the base part number suffix "PP" as shown on the engine decal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1630 Spark Plug: Description and Operation Spark Plug Construction PURPOSE Ignites the combustion mixture. LOCATION Threaded into the cylinder head, at the combustion chamber. OPERATION The spark plug provides a path for the high current of the secondary circuit to flow to ground. The only paths for this current are through the ground electrode and center electrode across the spark gap. The spark produced when the current jumps the gap and ignites the air/fuel mixture in the cylinder. Spark Plug Heat Range CONSTRUCTION The temperature of the spark plug is determined by the length of the insulator and the size of the heatsink area. The longer the insulator is, the smaller the heatsink area will be and this will cause the spark plug to be hotter. - Change high voltage pulses to spark at gap which ignites fuel and air mixture. - Have a platinum enhanced active electrode for long life. FEATURES The active electrode is different for LH and RH spark plugs: - On the RH side (cylinders 1, 2, 3, and 4) are type AWSF-32PG. - On the LH side (cylinders 5, 6, 7 and 8) are type AWSF-32P. NOTE: The replacement spark plugs are AWSF-32PP; both electrodes are platinum enhanced so it can replace either a RH or LH spark plug. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1631 Spark Plug: Testing and Inspection CLEANING AND INSPECTION Spark Plugs Inspect the electrodes and outer surface. Refer to Spark Plug Inspection Chart. Replace spark plugs if they are worn or damaged. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1632 Spark Plug: Adjustments Gapping Spark Plug Check and set the spark plug electrode gap to: 1.32-1.41 mm (0.052-0.056 inch) using an appropriate gapping tool. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1633 Spark Plug: Service and Repair REMOVAL NOTE: - If an original spark plug is reused, make sure it is placed in the same cylinder it was taken from. Replacement spark plugs can be used in any cylinder. - Use compressed air to remove any debris from the spark plug well before removing the spark plugs. 1. With a twisting, pulling motion disconnect the spark plug wire from the spark plug. 2. Squeeze the (A) locking tabs and disconnect the (B) spark plug wire from the (C) ignition coil. 3. Remove the RH spark plugs. 4. Remove the LH spark plugs. 5. Inspect the spark plugs for: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1634 - Deposits bridging spark plug gap (A). - Wet black deposits (oil fouling) (B). - Dry black deposits (carbon fouling) (C). - Overheating (D). - Deposits fused on spark plug (E). Pre-ignition damage (F). - Normal spark plug (G). INSTALLATION NOTE: If an original spark plug is reused, make sure it is placed in the same cylinder it was taken from. Replacement spark plugs can be used in any cylinder. 1. Apply Silicone Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A to inside of spark plug wire boots. 2. Adjust the spark plug gap as required. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1635 3. Install the LH spark plugs. 4. Install the RH spark plugs. 5. Connect the spark plug wires. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart above. If one or more cylinders reads low, squirt approximately one tablespoon of clean engine oil meeting Ford specification ESE-M2C153-E on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Gauge Check Compression Check: Testing and Inspection Gauge Check 1. Make sure the oil in the crankcase is of the correct viscosity and at the proper level and that the battery is properly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as Compression Tester in No.1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, use the auxiliary starter switch to crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Gauge Check > Page 1641 Compression Check: Testing and Inspection Interpreting Compression Readings 1. If compression improves considerably, the piston rings are faulty. 2. If compression does not improve, the valves are sticking or seating improperly. 3. If two adjacent cylinders indicate low compression pressures and squirting oil on the piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil and/or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75 percent of the highest reading. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Gauge Check > Page 1642 Compression Check: Testing and Inspection Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart above. If one or more cylinders reads low, squirt approximately one tablespoon of clean engine oil meeting Ford specification ESE-M2C153-E on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Gauge Check > Page 1643 Compression Check: Testing and Inspection Cylinder Leakage Test When a cylinder produces a low reading, the use of Engine Cylinder Leak Detection/Air Pressurization Kit will be helpful in pinpointing the exact cause. The leakage detector is inserted in the spark plug hole, the piston is brought up to dead center on the compression stroke, and compressed air is admitted. Once the combustion chamber is pressurized, a special gauge included in the kit will read the percentage of leakage. Leakage exceeding 20 percent is excessive. While the air pressure is retained in the cylinder, listen for the hiss of escaping air. A leak at the intake valve will be heard in the throttle body. A leak at the exhaust valve can be heard at the tail pipe. Leakage past the piston rings will be audible at the positive crankcase ventilation (PCV) connection. If air is passing through a blown head gasket to an adjacent cylinder, the noise will be evident at the spark plug hole of the cylinder into which the air is leaking. Cracks in the cylinder block or gasket leakage into the cooling system may be detected by a stream of bubbles in the radiator. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Hydraulic lash adjusters provide automatic lash compensation. No adjustment is necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1647 Valve Clearance: Adjustments Hydraulic lash adjusters provide automatic lash compensation. No adjustment is necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams Drive Belt: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1651 Drive Belt: Description and Operation This engine is equipped with a single drive belt and automatic drive belt tensioner. The accessory drive consists of the: ^ Drive belt. ^ Generator pulley. ^ Power steering pump pulley. ^ Crankshaft vibration damper and pulley. ^ A/C clutch pulley. ^ Belt idler pulley. ^ Drive belt tensioner. ^ Water pump pulley. The accessory drive: ^ Has a single serpentine drive belt. ^ Has automatic tensioning. ^ Is not adjustable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Drive Belt: Initial Inspection and Diagnostic Overview 1. Verify customer concern by running the engine. 2. Inspect the drive belts for chunking, fraying and wear. 3. Check the drive belts for correct routing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1654 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1655 Drive Belt: Component Tests and General Diagnostics Belt Tension NOTE: Drive belt tension is not adjustable. The drive belt tensioner automatically adjusts drive belt tension. Check the automatic drive belt tensioner: 1. With the engine off, check for proper drive belt routing. Service as required. 2. Rotate the drive belt tensioner and check for a binding or frozen condition. Replace components as required. Cracking/Chunking/Wear V-Ribbed Belt With Cracks (Acceptable) V-Ribbed Belt With Chunks Of Rib Missing (Not Acceptable) Under severe operating conditions (high temperatures, low humidity), drive belt rib cracking can occur at less than 48,000 km (30,000 miles). Drive belt rib cracking has no effect on belt performance. Drive belt "chunking" describes a condition when the rubber material actually chunks out between the rib cracks. The drive belt must be replaced if chunking occurs. Drive Belt Misalignment CAUTION: Incorrect drive belt installation will cause excessive drive belt wear and may cause the drive belt to come off the drive pulleys. Non-standard replacement drive belts may track differently or improperly. If a replacement drive belt tracks improperly, replace it with an original equipment drive belt to avoid performance failure or loss of belt. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1656 With the engine running, check drive belt tracking If the (A) edge of the drive belt rides beyond the edge of the pulleys, noise and premature wear may occur. Ensure the (B) drive belt rides correctly on the pulley. If a drive belt tracking condition exists, proceed with the following: Visually check the drive belt tensioner for damage, especially the mounting pad surface. If the drive belt tensioner is not installed correctly, the mounting surface pad will be out of position. This will result in chirp and squeal noises. ^ With the engine running, visually observe the grooves in the pulleys (not the pulley flanges) for excessive wobble. Replace components as required. ^ Check all accessories, mounting brackets and the drive belt tensioner for any interference that would prevent the component from mounting properly. Correct any interference condition and recheck belt tracking. ^ Tighten all accessories, mounting brackets, and drive belt tensioner retaining hardware to specification. Recheck the drive belt tracking. Drive Belt Noise/Flutter NOTE: Tensioner is shown in free-state position against arm travel stops. Drive belt chirp occurs due to pulley misalignment or excessive pulley runout. It can be the result of a damaged pulley or an improperly aligned pulley. To correct, determine the area where the noise comes from. Check each of the pulleys in that area with a straightedge to the crankshaft pulley, look for accessory pulleys out of position in the fore/aft direction or at an angle to the straightedge. Drive belt squeal is an intermittent noise that occurs when the drive belt slips on a pulley during certain conditions, such as engine start up, rapid engine acceleration, or A/C clutch engagement. Drive belt squeal can occur: 1. If the A/C discharge pressure goes above specifications: ^ The A/C system is overcharged. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1657 ^ The A/C condenser core airflow is blocked. 2. If the A/C OFF equalized pressure (the common discharge and suction pressure that occurs after several minutes) exceeds specifications. 3. If any of the accessories are damaged, or have a worn or damaged bearing or internal torsional resistance above normal. All accessories should be rotatable by hand in the unloaded condition. If not, inspect the accessory. 4. If fluid gets on the drive belt. This includes power steering fluid, engine coolant, engine oil or air conditioning system lubricant. If fluid does get on the drive belt during service, clean the drive belt with soap and water and thoroughly rinse with clean water. The drive belt does not have to be replaced if no apparent damage has occurred. 5. If the drive belt is too long. A drive belt that is too long will allow the drive belt tensioner arm to go all the way to the arm travel stop under certain load conditions, which will release tension to the drive belt. If the drive belt tensioner is resting on the stop, replace the drive belt. NOTE: The drive belt tensioner arm should rotate freely without binding. 6. If the drive belt tensioner is worn or damaged. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 1658 Drive Belt: Adjustments NOTE: Drive belt tension is not adjustable. The drive belt tensioner automatically adjusts drive belt tension. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 1659 Drive Belt: Service and Repair REMOVAL 1. Use (B) 1/2 inch square hole in drive belt tensioner pulley hub to rotate (A) drive belt tensioner clockwise and remove the (C) drive belt. INSTALLATION 1. Refer to the drive belt routing illustration for drive belt alignment. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Tube Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Outlet Tube REMOVAL 1. Remove the accelerator control splash shield. 1 Remove the accelerator control splash shield bolts. 2 Remove the accelerator control splash shield. 2. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 3. Disconnect the (A) positive crankcase ventilation hose and the (B) idle air control valve inlet tube. 4. Loosen the two air cleaner outlet tube hose clamp screws and remove the air cleaner outlet tube. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Tube > Page 1666 To install, reverse the removal procedure. CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Tube > Page 1667 Air Cleaner Fresh Air Duct/Hose: Service and Repair Removal and Installation REMOVAL 1. Open the (A) air cleaner clamp and set the (B) outlet engine air cleaner aside. 2. Lift the (B) open end of the (A) inlet engine air cleaner until free of the (C) engine air cleaner support insulators. CAUTION: The inlet engine air cleaner should be removed as an assembly. Do not separate the air cleaner from the fender inlet tube during removal or installation. 3. Pull the inlet engine air cleaner away from the inner fender. INSTALLATION CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. NOTE: The inlet engine air cleaner has an alignment tab which fits into a slot on the outlet engine air cleaner. This ensures a good seal and keeps unmetered air from entering the engine. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL 1. Open the (A) air cleaner clamp and set the (B) outlet engine air cleaner aside. 2. Remove the (A) air cleaner element from the (B) open end of the inlet engine air cleaner. INSTALLATION 1. Install the air cleaner element. NOTE: The inlet engine air cleaner has an alignment tab which fits into a slot on the outlet engine air cleaner. This ensures a good seal and keeps unmetered air from entering the engine. CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. 2. Position the engine air cleaner aligning the alignment tab. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1671 3. Close the air cleaner clamp. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair Note: Not all of these vehicles were equipped with a Cabin Air Filter. Only vehicles with a filter cover in the location shown have a Cabin Air Filter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 97-24-23 > Nov > 97 > Engine - Stall During Transmission Engagement Fluid Filter - A/T: Customer Interest Engine - Stall During Transmission Engagement Article No. 97-24-23 11/24/97 ^ STALL - ENGINE STALL DURING TRANSMISSION ENGAGEMENT - VEHICLES EQUIPPED WITH E4OD TRANSMISSION ^ TRANSMISSION - E4OD - ENGINE STALL DURING ENGAGEMENT LIGHT TRUCK: 1996 BRONCO 1996-97 ECONOLINE, F-150-350 SERIES, F-53 MOTORHOME 1997 EXPEDITION 1998 NAVIGATOR This TSB article is being republished in its entirety to revise the Service Procedure. ISSUE: Some vehicles may stall when the transmission is placed into gear. This may be caused by the transmission fluid filter becoming detached and/or loose. ACTION: Install a new design fluid filter and seal assembly. The new design has legs molded into the plastic filter cover (Figure 1). This new design filter does not require using the rectangular transmission pan magnet. SERVICE PROCEDURE Follow all the normal diagnostic procedures outlined in the appropriate model/year Service Manual. Repair as required. If all normal diagnostics fail to correct the problem, refer to the following Steps. 1. Remove the transmission fluid pan to determine if the transmission fluid filter has dropped down or is not firmly seated in the pump bore. 2. If the filter has dropped down into the pan, discard the filter assembly and remove the filter seal from the pump bore. CAUTION: BE CAREFUL NOT TO SCRATCH OR DAMAGE THE PUMP BORE WHEN REMOVING THE SEAL. NOTE: DO NOT REMOVE THE ORIGINAL FLUID PAN MAGNET FROM THE FLUID PAN OTHER THAN TO CLEAN AND REINSTALL. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 97-24-23 > Nov > 97 > Engine - Stall During Transmission Engagement > Page 1683 3. Install a new Filter and Seal Assembly (F6TZ-7A098-AB: 4X2, F6TZ-7A098-BB: 4X4). Refer to Figure 1. CAUTION: DO NOT USE THE RECTANGULAR TRANSMISSION PAN MAGNET WHEN USING EITHER OF THESE NEW DESIGN FILTER AND SEAL ASSEMBLIES. CAUTION: DO NOT REPLACE A REUSABLE PAN GASKET WITH A CORK GASKET, THIS MAY RESULT IN A TRANSMISSION FLUID LEAK. CLEAN AND REUSE UNLESS DAMAGED. REPLACE CORK GASKET WITH CORK GASKETS. 4. Refill transmission as required using MERCON(R) Multi-Purpose Automatic Transmission Fluid (ATF) (XT-2-QDX). PART NUMBER PART NAME F6TZ-7A098-AB Filter And Seal Assembly (4X2) F6TZ-7A098-BB Filter And Seal Assembly (4X4) XT-2-QDX MERCON(R) Multi-Purpose Automatic Transmission Fluid (ATF) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-18-7 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 972423A Remove And Install Pan 0.7 Hr. To Replace Filter And Seal Assembly 972423B Additional Time To Clean, 0.1 Hr. Inspect, And Reuse Elastomeric Reusable Pan Gasket DEALER CODING CONDITION BASIC PART NO. CODE 7A098 33 OASIS CODES: 503000, 504000, 607000, 607400 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 97-15-21 > Jul > 97 > Engine - Stalls When Transmission is Engaged Fluid Filter - A/T: Customer Interest Engine - Stalls When Transmission is Engaged Article No. 97-15-21 07/21/97 ^ STALL - ENGINE STALL DURING TRANSMISSION ENGAGEMENT - VEHICLES EQUIPPED WITH E40D TRANSMISSION ^ TRANSMISSION - E4OD - ENGINE STALL DURING ENGAGEMENT LIGHT TRUCK: 1996 BRONCO 1996-97 ECONOLINE, F-150-350 SERIES, F-53 MOTORHOME CHASSIS 1997 EXPEDITION 1998 NAVIGATOR ISSUE: Some vehicles may stall when the transmission is placed into gear. This may be caused by the transmission fluid filter becoming detached and/or loose. ACTION: Install a rectangular fluid pan magnet under the transmission fluid filter to keep the filter in place and reduce the possibility of the filter becoming loose. Refer to the following Service Procedure for details. SERVICE PROCEDURE Follow all the normal diagnostic procedures outlined in the appropriate model/year Service Manual. Repair as required. If all normal diagnostics fail to correct the problem, refer to the following Steps. 1. Remove the transmission fluid pan to determine if the transmission fluid filter has dropped down or is not firmly seated in the pump bore. 2. If the filter is not firmly seated in the pump bore or falls down into the fluid pan when the pan is removed, place the rectangular Transmission Pan Magnet (F3RZ-7E290-AC) on the pan at the location shown in Figure 1. NOTE: DO NOT REMOVE THE ORIGINAL FLUID PAN MAGNET FROM THE FLUID PAN OTHER THAN TO CLEAN AND REINSTALL. CAUTION: DO NOT USE THE ORIGINAL FLUID PAN MAGNET TO HOLD THE FILTER IN PLACE. IT IS TOO THICK AND MAY CAUSE A LEAK. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 97-15-21 > Jul > 97 > Engine - Stalls When Transmission is Engaged > Page 1688 3. Install a new Filter and Seal Assembly (E9TZ-7A098-A). CAUTION: DO NOT REMOVE AND REPLACE THE REUSABLE PAN GASKET OR REPLACE IT WITH A CORK GASKET, THIS MAY RESULT IN A LEAK CONDITION. 4. Refill transmission as required using MERCON(R) Multi-Purpose Automatic Transmission Fluid (ATF) (XT-2-ODX). PART NUMBER PART NAME F3PZ-E290-AC Transmission Pan Magnet XT-2-ODX MERCON(R) Multi-Purpose Automatic Transmission Fluid (ATF) E9TZ-7A098-A Filter And Seal Assembly OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971521A Install New Pan Magnet 0.7 Hr. 971521B Additional Time To Clean, 0.1 Hr. Inspect, And Reuse Elastomeric Reusable Pan Gasket DEALER CODING CONDITION BASIC PART NO. CODE 7A098 33 OASIS CODES: 502000, 503000, 504000, 607000, 607400 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 97-24-23 > Nov > 97 > Engine - Stall During Transmission Engagement Fluid Filter - A/T: All Technical Service Bulletins Engine - Stall During Transmission Engagement Article No. 97-24-23 11/24/97 ^ STALL - ENGINE STALL DURING TRANSMISSION ENGAGEMENT - VEHICLES EQUIPPED WITH E4OD TRANSMISSION ^ TRANSMISSION - E4OD - ENGINE STALL DURING ENGAGEMENT LIGHT TRUCK: 1996 BRONCO 1996-97 ECONOLINE, F-150-350 SERIES, F-53 MOTORHOME 1997 EXPEDITION 1998 NAVIGATOR This TSB article is being republished in its entirety to revise the Service Procedure. ISSUE: Some vehicles may stall when the transmission is placed into gear. This may be caused by the transmission fluid filter becoming detached and/or loose. ACTION: Install a new design fluid filter and seal assembly. The new design has legs molded into the plastic filter cover (Figure 1). This new design filter does not require using the rectangular transmission pan magnet. SERVICE PROCEDURE Follow all the normal diagnostic procedures outlined in the appropriate model/year Service Manual. Repair as required. If all normal diagnostics fail to correct the problem, refer to the following Steps. 1. Remove the transmission fluid pan to determine if the transmission fluid filter has dropped down or is not firmly seated in the pump bore. 2. If the filter has dropped down into the pan, discard the filter assembly and remove the filter seal from the pump bore. CAUTION: BE CAREFUL NOT TO SCRATCH OR DAMAGE THE PUMP BORE WHEN REMOVING THE SEAL. NOTE: DO NOT REMOVE THE ORIGINAL FLUID PAN MAGNET FROM THE FLUID PAN OTHER THAN TO CLEAN AND REINSTALL. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 97-24-23 > Nov > 97 > Engine - Stall During Transmission Engagement > Page 1694 3. Install a new Filter and Seal Assembly (F6TZ-7A098-AB: 4X2, F6TZ-7A098-BB: 4X4). Refer to Figure 1. CAUTION: DO NOT USE THE RECTANGULAR TRANSMISSION PAN MAGNET WHEN USING EITHER OF THESE NEW DESIGN FILTER AND SEAL ASSEMBLIES. CAUTION: DO NOT REPLACE A REUSABLE PAN GASKET WITH A CORK GASKET, THIS MAY RESULT IN A TRANSMISSION FLUID LEAK. CLEAN AND REUSE UNLESS DAMAGED. REPLACE CORK GASKET WITH CORK GASKETS. 4. Refill transmission as required using MERCON(R) Multi-Purpose Automatic Transmission Fluid (ATF) (XT-2-QDX). PART NUMBER PART NAME F6TZ-7A098-AB Filter And Seal Assembly (4X2) F6TZ-7A098-BB Filter And Seal Assembly (4X4) XT-2-QDX MERCON(R) Multi-Purpose Automatic Transmission Fluid (ATF) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-18-7 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 972423A Remove And Install Pan 0.7 Hr. To Replace Filter And Seal Assembly 972423B Additional Time To Clean, 0.1 Hr. Inspect, And Reuse Elastomeric Reusable Pan Gasket DEALER CODING CONDITION BASIC PART NO. CODE 7A098 33 OASIS CODES: 503000, 504000, 607000, 607400 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 97-15-21 > Jul > 97 > Engine - Stalls When Transmission is Engaged Fluid Filter - A/T: All Technical Service Bulletins Engine - Stalls When Transmission is Engaged Article No. 97-15-21 07/21/97 ^ STALL - ENGINE STALL DURING TRANSMISSION ENGAGEMENT - VEHICLES EQUIPPED WITH E40D TRANSMISSION ^ TRANSMISSION - E4OD - ENGINE STALL DURING ENGAGEMENT LIGHT TRUCK: 1996 BRONCO 1996-97 ECONOLINE, F-150-350 SERIES, F-53 MOTORHOME CHASSIS 1997 EXPEDITION 1998 NAVIGATOR ISSUE: Some vehicles may stall when the transmission is placed into gear. This may be caused by the transmission fluid filter becoming detached and/or loose. ACTION: Install a rectangular fluid pan magnet under the transmission fluid filter to keep the filter in place and reduce the possibility of the filter becoming loose. Refer to the following Service Procedure for details. SERVICE PROCEDURE Follow all the normal diagnostic procedures outlined in the appropriate model/year Service Manual. Repair as required. If all normal diagnostics fail to correct the problem, refer to the following Steps. 1. Remove the transmission fluid pan to determine if the transmission fluid filter has dropped down or is not firmly seated in the pump bore. 2. If the filter is not firmly seated in the pump bore or falls down into the fluid pan when the pan is removed, place the rectangular Transmission Pan Magnet (F3RZ-7E290-AC) on the pan at the location shown in Figure 1. NOTE: DO NOT REMOVE THE ORIGINAL FLUID PAN MAGNET FROM THE FLUID PAN OTHER THAN TO CLEAN AND REINSTALL. CAUTION: DO NOT USE THE ORIGINAL FLUID PAN MAGNET TO HOLD THE FILTER IN PLACE. IT IS TOO THICK AND MAY CAUSE A LEAK. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 97-15-21 > Jul > 97 > Engine - Stalls When Transmission is Engaged > Page 1699 3. Install a new Filter and Seal Assembly (E9TZ-7A098-A). CAUTION: DO NOT REMOVE AND REPLACE THE REUSABLE PAN GASKET OR REPLACE IT WITH A CORK GASKET, THIS MAY RESULT IN A LEAK CONDITION. 4. Refill transmission as required using MERCON(R) Multi-Purpose Automatic Transmission Fluid (ATF) (XT-2-ODX). PART NUMBER PART NAME F3PZ-E290-AC Transmission Pan Magnet XT-2-ODX MERCON(R) Multi-Purpose Automatic Transmission Fluid (ATF) E9TZ-7A098-A Filter And Seal Assembly OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971521A Install New Pan Magnet 0.7 Hr. 971521B Additional Time To Clean, 0.1 Hr. Inspect, And Reuse Elastomeric Reusable Pan Gasket DEALER CODING CONDITION BASIC PART NO. CODE 7A098 33 OASIS CODES: 502000, 503000, 504000, 607000, 607400 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Page 1700 Fluid Filter - A/T: Service and Repair NOTE: MERCON Automatic Transmission Fluid is being replaced by MERCON V as a service fluid. REMOVAL 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Place a drain pan under the transmission fluid pan. 3. Drain the transmission fluid. - Loosen the transmission fluid pan bolts and allow the fluid to drain. After the fluid is drained remove the bolts. 4. Remove the (A) transmission fluid pan and the (B) transmission pan gasket. 5. Pull down evenly and remove the transmission fluid filter and seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Page 1701 6. Remove the converter housing access plug. 7. Remove the torque converter drain plug and drain the torque converter. - Rotate the crankshaft to access the drain plug. 8. Clean and inspect the (A) transmission fluid pan, the (B) transmission pan gasket and the (C) magnet. 9. Flush the torque converter, cooler, and cooler lines. INSTALLATION 1. Install the new torque converter drain plug. NOTE: A new torque converter drain plug must be installed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Page 1702 2. Install the converter housing access plug. 3. Replace the fluid filter and seal as required. CAUTION: If replacing the filter, and the seal remains in the main control bore, carefully use a small screwdriver to remove the seal. Use care not to damage the main control bore. NOTE: If the transmission is being repaired for a contamination-related failure, use a new filter and seal. The filter may be reused if no excessive contamination is present. 4. Position the pan magnet into the transmission fluid pan. 5. Install the transmission fluid pan and gasket. (1) Position the transmission pan gasket. (2) Position the transmission fluid pan. NOTE: The transmission pan gasket is reusable. Clean and inspect for damage; if not damaged, reuse the gasket. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Page 1703 6. Install the transmission fluid pan bolts. 7. Remove supports and lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. 8. Fill the transmission to the proper fluid level. - Use Motorcraft MERCON or MERCON V Automatic Transmission Fluid or equivalent meeting FORD specification. NOTE: When filling a dry transmission and converter start with a minimum of 4.7 liters (5 quarts). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Locations Fuel Pressure Release: Locations Fuel Pressure Port (Typical) A fuel system service port is provided on the fuel rail. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Locations > Page 1708 Fuel Pressure Release: Service Precautions WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited, resulting in possible injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. - Before repairing or disconnecting any of the fuel lines or fuel system components, the fuel system fuel pressure release procedure must be performed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Locations > Page 1709 Fuel Pressure Release: Service and Repair Fuel Pressure Port (Typical) 1. Remove the schrader valve cap and attach EFI/CFI Fuel Pressure Gauge. 2. Open the manual valve on EFI/CFI Fuel Pressure Gauge and Perform Fuel Pressure Release. NOTE: Open manual value slowly to relieve system pressure. - This will drain some fuel out of the system. - Place fuel in suitable a container. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Description and Operation Fuel Pump Pickup Filter: Description and Operation Fuel Pump Module A nylon filter element: - is mounted on the electric fuel pump inlet inside the fuel tank. - is used to protect the fuel pump from fuel tank contaminants. - is NOT available separately. To service the in-tank filter, replace the fuel pump and sender assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Description and Operation > Page 1713 Fuel Pump Pickup Filter: Service and Repair The nylon filter element is NOT available separately. To service the in-tank filter, replace the fuel pump and sender assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications Oil Filter: Specifications TORQUE SPECIFICATIONS Oil Filter ............................................................................................................................................... ................................... 14-17 Nm (10-12.5 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement Technical Service Bulletin # 98-12-5 Date: 980622 A/C - Filtering Refrigerant After Compressor Replacement Article No. 98-12-5 06/22/98 AIR CONDITIONING - FILTERING REFRIGERANT AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86 CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII 1995-98-MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150, F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98 EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to revise the Service Procedure and to update the model years. ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the refrigerant system cleaned to remove any debris or contaminants that may be present to prevent damage to the replacement compressor. ACTION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 1721 Install a Service Filter Kit in the refrigerant system prior to installing the replacement compressor. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-15-5 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-99 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models And Major Component Warranty Coverage For All Other Lincoins OPERATION DESCRIPTION TIME 981205A Kit Installation 1.2 Hrs. 981205B Extra Time For Refrigerant 0.4 Hr. (R-12) Recovery DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208999 Service Procedure THIS PROCEDURE IS OPTIONAL IF THE SYSTEM IS FLUSHED USING THE ROTUNDA A/C FLUSHER. CAUTION THIS FILTERING PROCEDURE MAY BE USED FOR EITHER R-12 OR R-134a REFRIGERANT SYSTEMS. BECAUSE THE TWO (2) SYSTEMS USE DIFFERENT REFRIGERANT OILS AND BECAUSE THE COMPRESSOR COULD BE DAMAGED IF THE WRONG OIL IS USED, SYSTEM IDENTIFICATION IS VERY IMPORTANT. BE SURE SYSTEM IS CORRECTLY IDENTIFIED BEFORE STARTING THE FILTERING PROCEDURE. Each Service Filter Kit includes the following items: ^ One (1) Pancake Filter (to be installed in the liquid line between the condenser and the orifice tube) ^ One (1) Instruction Sheet NOTE ON 1993-94 RANGER/EXPLORER VEHICLES, TECHNICIANS MAY EXPERIENCE DIFFICULTY WHEN CONNECTING THE PANCAKE FILTER HOSE FITTINGS TO THE EVAPORATOR INLET WITH THE ORIFICE TUBE INSTALLED. REMOVE THE OFFICE TUBE AND RUN THE SYSTEM FOR 1 HOUR AS DESCRIBED IN THE FILTERING PROCEDURE. REINSTALL THE ORIFICE TUBE AFTER FILTERING IS COMPLETE. CAUTION FOLLOW ALL REFRIGERANT SYSTEM SAFETY AND SERVICE PRECAUTIONS OUTLINED IN THE APPROPRIATE SERVICE OR WORKSHOP MANUAL. 1. Before removing any refrigerant system components, recover the refrigerant from the system following the recycling methods outlined In the appropriate Service/Workshop Manual. 2. Remove the suction accumulator/drier assembly and drain the oil into a calibrated container. 3. Install a new suction accumulator/drier and add new refrigerant oil to replace the old oil. The quantity of the new oil to be added is the amount to match that drained from the old accumulator plus 60 mL (2 oz). Refer to the Dealer Master Parts Catalog for the correct suction accumulator/drier part number. CAUTION REMEMBER TO USE MOTORCRAFT YN-9-A REFRIGERANT COMPRESSOR OIL WITH R-12 SYSTEMS AND MOTORCRAFT YN-12-C REFRIGERANT COMPRESSOR OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. 4. Install a new orifice tube. Refer to the Dealer Master Parts Catalog for the correct orifice tube part number. If the orifice tube in the vehicle is located in the liquid line between the condenser and the evaporator, replace the liquid line assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 1722 5. Install pancake filter in the liquid line between the condenser and the orifice tube, Figure 1. a. Be sure orifice inlet is toward the condenser. b. Connections can be made using Test Adapter Set D93L-19703-B, or equivalent, and flexible refrigerant hose of 2500 psi burst rating. Individual fittings are also available. 6. Remove the old compressor following Service/Workshop Manual procedures. Drain the oil into a calibrated container. 7. Drain the oil from the replacement compressor into a clean calibrated container. NOTE: IT WILL BE NECESSARY TO TRANSFER THE MAGNET CLUTCH FROM THE OLD COMPRESSOR TO THE REPLACEMENT COMPRESSOR. FOLLOW SERVICE/WORKSHOP MANUAL PROCEDURES. 8. A new FX-15 service compressor contains 207 mL (7 oz.) of R-12 refrigerant oil. A new FS-10 service compressor does not contain any oil and can be used with an R-12 or an R-134a system. CAUTION REMEMBER TO USE YN-9-A (MINERAL) OIL WITH R-12 SYSTEMS AND YN-12-C (PAG) OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. ^ If the amount of oil drained from the removed compressor is between 90 and 148 mL (3-5 oz), pour the same amount of clean refrigerant oil into the new compressor. ^ If the amount of oil drained from the old compressor is greater than 90 mL (3 oz), pour 90 mL (3 oz) of clean refrigerant oil into the new compressor. 9. Install the new compressor following Service/Workshop Manual procedures. Make sure all mounting bolts are tightened properly. Check the tension of the compressor drive belt. Adjust if necessary. 10. Evacuate, charge and leak test the system, following Service/Workshop Manual procedures. 11. Check all refrigerant system hoses, lines and the position of the newly-installed filters to make sure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments. 12. Set the A/C control on Max A/C, high blower and temperature control at full cold. a. Start engine and let idle briefly. b. Be sure A/C system is operating properly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 1723 13. Gradually bring the engine up to 1200 rpm by running it at lower rpms for short periods (first at 800 rpm, then at 1000 rpm). Set the engine at 1200 rpm and run it for an hour with the A/C system operating. 14. Stop the engine. NOTE: IT WILL BE NECESSARY TO RECOVER THE SYSTEM REFRIGERANT CHARGE BEFORE PROCEEDING. 15. Allow the engine to cool sufficiently to remove the fittings, flexible hoses and pancake filter from the liquid line. 16. Discard the filter. It can be used one (1) tie only. 17. Reconnect the liquid line back into the system. 18. Evacuate, charge and leak test the system. Make any necessary adjustments. 19. Check the operation of the system in all models. PART NUMBER PART NAME F8VZ-19E773-AA Filter Kit F73Z-19577-AA Refrigerant Oil - Motorcraft YN-9-A (For R-12 Refrigerant Systems Only) F7AZ-19589-DA Refrigerant Oil - Motorcraft YN-12-C (PAG-Type Oil For R-134a Refrigerant Systems Only) NOTE THE TOTAL REPAIR TIME IS FOR INSTALLING SERVICE FILTER KIT PER INSTRUCTIONS THIS INCLUDES INSTALLATION OF AND DISCARD OF FILTER. REFER TO SERVICE LABOR TIME STANDARDS MANUALS IF ADDITIONAL LABOR OPERATIONS ARE REQUIRED. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 1733 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 1734 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 1740 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 1741 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes - Service Tip. Heater Hose: All Technical Service Bulletins Rear Air Conditioning Lines/Tubes - Service Tip. Article No. 97-14-20 07/07/97 ^ AIR CONDITIONING - REAR AUXILIARY UNDERBODY A/C LINES AND TUBES - SERVICE TIP ^ COOLING SYSTEM - REAR AUXILIARY UNDERBODY HEATER LINES AND TUBES SERVICE TIP LIGHT TRUCK: 1997 EXPEDITION ISSUE: Additional information has been released by Ford Motor Company regarding the servicing of the underbody tubes and hoses for the rear auxiliary A/C and heater systems. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes - Service Tip. > Page 1746 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes - Service Tip. > Page 1747 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes - Service Tip. > Page 1748 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes - Service Tip. > Page 1749 ACTION: When servicing the underbody tubes and hoses for the rear auxiliary A/C and heater, refer to the following illustrations (Figures 1-4) to determine correct part number and part locations. Refer to the 1997 Expedition Workshop Manual for all part removal and installation procedures. PART NUMBER PART NAME F75Z-18663-KA Front Heater Outlet Tube Kit F75Z-18696-KA Front Heater Inlet Tube Kit F75Z-18663-LA Rear Heater Outlet Tube Kit F75Z-18696-LA Hear Heater Inlet Tube Kit F75Z-19867-KA Rear A/C Suction Tube Kit F75Z-19835-JA Rear A/C Liquid Tube Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes - Service Tip. > Page 1750 OASIS CODES: 208100, 208200, 208999, 290000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes - Service Tip. Heater Hose: All Technical Service Bulletins Rear Air Conditioning Lines/Tubes - Service Tip. Article No. 97-14-20 07/07/97 ^ AIR CONDITIONING - REAR AUXILIARY UNDERBODY A/C LINES AND TUBES - SERVICE TIP ^ COOLING SYSTEM - REAR AUXILIARY UNDERBODY HEATER LINES AND TUBES SERVICE TIP LIGHT TRUCK: 1997 EXPEDITION ISSUE: Additional information has been released by Ford Motor Company regarding the servicing of the underbody tubes and hoses for the rear auxiliary A/C and heater systems. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes - Service Tip. > Page 1756 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes - Service Tip. > Page 1757 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes - Service Tip. > Page 1758 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes - Service Tip. > Page 1759 ACTION: When servicing the underbody tubes and hoses for the rear auxiliary A/C and heater, refer to the following illustrations (Figures 1-4) to determine correct part number and part locations. Refer to the 1997 Expedition Workshop Manual for all part removal and installation procedures. PART NUMBER PART NAME F75Z-18663-KA Front Heater Outlet Tube Kit F75Z-18696-KA Front Heater Inlet Tube Kit F75Z-18663-LA Rear Heater Outlet Tube Kit F75Z-18696-LA Hear Heater Inlet Tube Kit F75Z-19867-KA Rear A/C Suction Tube Kit F75Z-19835-JA Rear A/C Liquid Tube Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes - Service Tip. > Page 1760 OASIS CODES: 208100, 208200, 208999, 290000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Page 1761 Heater Hose: Specifications Hose Clamp ......................................................................................................................................... ........................................ 1.6-2.2 N.m (17-22 Lb/In) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Page 1762 Heater Hose: Description and Operation The supply lines are one-piece tubes that are secured to the underbody of the vehicle. Replacement kits are only available with multiple-piece lines for ease of installation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Outlet Tube Heater Hose: Service and Repair Front Outlet Tube Heater Hose Disconnect Tool Special Tools REMOVAL 1. Drain the cooling system. 2. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 3. Remove the RH front fender splash shield. 1. Remove the five screws. 2. Remove the three pushpins. 3. Remove the front fender splash shield. 4. Remove the four tube brackets. 1. Remove the nuts. 2. Remove the bracket by inserting a screw driver in the bracket slot and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the tubes. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 1765 5. Disconnect the heater outlet tube from the outlet hose. ^ Use Heater Hose Disconnect Tool to disconnect the hose. 6. Disconnect the front auxiliary heater outlet tube from the rear auxiliary heater outlet tube. 1. Remove the nut. 2. Disconnect the line. 7. Cut the heater outlet tube in the positions shown. 8. Remove and discard the cut sections. INSTALLATION 1. Install the heater outlet tube. ^ In stall the end with blue tape over the frame. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 1766 2. Install the heater outlet tube. ^ Install the end with red tape over the frame and the end with yellow tape between the frame and the body vertical flange. 3. Connect the heater water outlet tubes. 1. Connect the fitting. 2. Loosely install the nut. 4. Install the heater water outlet tube. ^ Install the tube through the wheel opening. 5. Connect the heater water outlet tubes. 1. Connect the fitting. 2. Loosely install the nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 1767 6. Tighten the two peanut fittings. 7. Install the tube brackets. 1. Position the bracket. 2. Install the nut. ^ Snap the tube into the bracket. CAUTION: Insure that clearance exists between the frame and the tubes. NOTE: The bracket must be positioned equally between the white location marks on the tube. 8. Connect heater water outlet tube to engine heater outlet hose. 9. Install the front fender splash shield. 10. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 1768 11. Fill the cooling system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 1769 Heater Hose: Service and Repair Rear Inlet Tube Heater Hose Disconnect Tool Special Tools REMOVAL 1. Drain the cooling system. 2. Remove the quarter trim panel access cover. 3. Disconnect the heater inlet hose. ^ Use Heater Hose Disconnect Tool to disconnect the inlet hose. 4. Remove the auxiliary A/C line grommet retainer. 1. Remove the bolts. 2. Remove the retainer. 5. Remove the spare tire. 6. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 1770 7. Lower the muffler heat shield. 1. Remove the two front bolts. 2. Lower the heat shield. 8. Remove the four tube brackets. 1. Remove the nuts. 2. Remove the bracket by inserting a screw driver in the bracket slot and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the tubes. 9. Cut the tube in the positions shown. 10. Remove and discard the cut sections. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 1771 1. Install the heater inlet tube. ^ Install the end with green tape over the axle between the frame and body. 2. Connect the heater inlet tube to the front auxiliary line. 1. Connect the inlet tube. 2. Loosely install the nut. 3. Install the heater inlet tube. ^ Install the end with blue tape between the frame crossmember and the floor pan. 4. Connect the heater inlet tubes. 1. Connect the fittings. 2. Loosely install the nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 1772 5. Install the heater inlet tube. ^ In stall the end with red tape between the frame and the body. 6. Connect the heater tubes. 1. Connect the fittings. 2. Loosely install the nut. 7. Install the heater inlet rube. ^ Install the end with green tape through the floor opening. 8. Connect the heater inlet tubes. 1. Connect the fittings. 2. Loosely install the nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 1773 9. Tighten the four peanut fittings. 10. Install the tube brackets. 1. Position the bracket. 2. Install the nut. ^ Snap the tube into the bracket. NOTE: The bracket must be positioned equally between the white location marks on the tube. 11. Install the muffler heat shield. 1. Position the shield. 2. Install the nuts 12. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. 13. Install the grommet tube seal and retainer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 1774 NOTE: Insure that the tubes are entering through the center of the floor opening and that the retainer locating marks are positioned correctly. 14. Connect the heater inlet hose to the auxiliary heater core. 15. Install the quarter trim access panel. 16. Install the spare tire. 17. Fill the cooling system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 1775 Heater Hose: Service and Repair Rear Outlet Tube Heater Hose Disconnect Tool Special Tools REMOVAL 1. Drain the cooling system. 2. Remove the quarter trim panel access cover. 3. Disconnect the heater outlet hose. ^ Use Heater Hose Disconnect Tool to disconnect the outlet hose. 4. Remove the auxiliary A/C line grommet retainer. 1. Remove the bolts. 2. Remove the retainer. 5. Remove the spare tire. 6. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 1776 7. Lower the muffler heat shield. 1. Remove the two front bolts. 2. Lower the heat shield. 8. Remove the four tube brackets. 1. Remove the nuts. 2. Remove the bracket by inserting a screw driver in the bracket slot and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off. 9. Cut the tube in the positions shown. 10. Remove and discard the cut sections. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 1777 1. Install the heater outlet tube. ^ Install the end with blue tape over the axle between the frame and the body. 2. Connect the heater outlet tube to the front auxiliary tube. 1. Connect the fittings. 2. Loosely install the nut. 3. Install the heater outlet tube. ^ Install the end with red tape between the frame and the crossmember. 4. Connect the heater outlet tubes. 1. Connect the fittings. 2. Loosely install the nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 1778 5. Install the heater outlet tube. ^ Install the end with blue tape between the frame and body. 6. Connect the heater outlet tubes. 1. Connect the fittings. 2. Loosely install the nut. 7. Install the heater outlet tube. ^ Install the end with the hose through the floor opening. 8. Tighten the four peanut fittings. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 1779 9. Install the tube brackets. 1. Position the bracket. 2. Install the nut. ^ Snap the tube into the bracket. NOTE: The bracket must be positioned equally between the white location marks on the tube. 10. Install the muffler heat shield. 1. Position the shield. 2. Install the nuts. 11. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. 12. Install the grommet tube seal and retainer. NOTE: Insure that the tubes are entering through the center of the floor opening and that the retainer locating marks are positioned correctly. 13. Connect the heater outlet hose to the auxiliary heater core. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 1780 14. Install the quarter trim access panel. 15. Install the spare tire. 16. Fill the cooling system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 1781 Heater Hose: Service and Repair Removal and Installation REMOVAL 1. Drain the radiator. 2. Disconnect the heater outlet hose at the engine. 3. Disconnect the heater inlet hose at the engine. 1. Loosen the hose clamp. 2. Disconnect the heater inlet hose. 4. Compress the holding tabs and disconnect the heater water hoses at the heater core. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 1782 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Rear Air Conditioning Lines/Tubes - Service Tip. Hose/Line HVAC: Technical Service Bulletins Rear Air Conditioning Lines/Tubes - Service Tip. Article No. 97-14-20 07/07/97 ^ AIR CONDITIONING - REAR AUXILIARY UNDERBODY A/C LINES AND TUBES - SERVICE TIP ^ COOLING SYSTEM - REAR AUXILIARY UNDERBODY HEATER LINES AND TUBES SERVICE TIP LIGHT TRUCK: 1997 EXPEDITION ISSUE: Additional information has been released by Ford Motor Company regarding the servicing of the underbody tubes and hoses for the rear auxiliary A/C and heater systems. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Rear Air Conditioning Lines/Tubes - Service Tip. > Page 1787 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Rear Air Conditioning Lines/Tubes - Service Tip. > Page 1788 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Rear Air Conditioning Lines/Tubes - Service Tip. > Page 1789 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Rear Air Conditioning Lines/Tubes - Service Tip. > Page 1790 ACTION: When servicing the underbody tubes and hoses for the rear auxiliary A/C and heater, refer to the following illustrations (Figures 1-4) to determine correct part number and part locations. Refer to the 1997 Expedition Workshop Manual for all part removal and installation procedures. PART NUMBER PART NAME F75Z-18663-KA Front Heater Outlet Tube Kit F75Z-18696-KA Front Heater Inlet Tube Kit F75Z-18663-LA Rear Heater Outlet Tube Kit F75Z-18696-LA Hear Heater Inlet Tube Kit F75Z-19867-KA Rear A/C Suction Tube Kit F75Z-19835-JA Rear A/C Liquid Tube Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Rear Air Conditioning Lines/Tubes - Service Tip. > Page 1791 OASIS CODES: 208100, 208200, 208999, 290000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 1792 Hose/Line HVAC: Specifications Tube Bracket Nut ................................................................................................................................. ........................................... 10-14 N.m (8-10 Lb/Ft) A/C Line Bracket Nuts ......................................................................................................................... ....................................... 6.8-9.2 N.m (61-82 Lb/In) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 1793 Hose/Line HVAC: Description and Operation The supply lines are one-piece tubes that are secured to the underbody of the vehicle. Replacement kits are only available with multiple-piece lines for ease of installation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Condenser to Evaporator Line Hose/Line HVAC: Service and Repair Condenser to Evaporator Line Spring Lock Coupling Disconnect Tool Set Spring Lock Coupling Disconnect Tool (5/8 Inch) Spring Lock Coupling Spring Lock Coupling Special Tools REMOVAL 1. Disconnect the battery ground cable. 2. Recover the refrigerant from the system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Condenser to Evaporator Line > Page 1796 3. Remove the line clip at the evaporator connection. 4. Fit Spring Lock Coupling Disconnect Tool to the condenser lines so that the spring lock coupling tool can enter the cage opening to release the A/C tube lock coupling spring. 5. Push the tool into the cage opening to release the female fitting from the A/C tube lock coupling spring. 6. Pull the spring lock coupling fittings apart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Condenser to Evaporator Line > Page 1797 7. Disconnect the A/C condenser core lower line. 1. Remove the nut. 2. Disconnect the A/C condenser core lower line. 8. Remove the tube bracket nut. 9. Remove the suction accumulator/drier bracket clamping bolt. 10. Remove the evaporator to condenser tube. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Condenser to Evaporator Line > Page 1798 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Condenser to Evaporator Line > Page 1799 Hose/Line HVAC: Service and Repair A/C Auxiliary Evaporator Hoses Outlet Tube - (5/8 In) REMOVAL 1. Recover the refrigerant from the A/C system. See: Heating and Air Conditioning/Service and Repair/Refrigerant Recovery 2. Remove the quarter trim panel access cover. 3. Disconnect the outlet tube from the underbody line. 1. Remove the nut. 2. Remove the line. 4. Remove the auxiliary A/C line grommet retainer. 1. Remove the bolts. 2. Remove the retainer. 5. Remove the spare tire. 6. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 7. Remove the four tube brackets. 1. Remove the nuts. 2. Remove the bracket by inserting a screw driver in the bracket slot and twisting. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Condenser to Evaporator Line > Page 1800 CAUTION: Pull the bracket off the stud before attempting to pry it off the tubes. 8. Disconnect the (5/8 in) outlet tube peanut fitting. 1. Remove the nut. 2. Disconnect the line. 9. Cut the (5/8 in) outlet tube in four places. 10. Remove and discard the line. INSTALLATION 1. Install the outlet line over frame. ^ Install the end with purple tape in-between frame and body. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Condenser to Evaporator Line > Page 1801 2. Connect the outlet line peanut fitting. 1. Connect the outlet lines. 2. Loosely install the nut. 3. Install the outlet line. ^ Install the end with the purple tape between the frame and body. 4. Connect the outlet line peanut fitting to outlet line over frame. 1. Connect the outlet lines. 2. Loosely install the nut. 5. Install the outlet line over frame. ^ Install the end with yellow tape. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Condenser to Evaporator Line > Page 1802 6. Connect the outlet line peanut fitting to outlet line over frame. ^ Connect the fitting and loosely install the nut. 7. Install the outlet line. ^ Install the end with orange tape between the frame and body near rear wheel opening. 8. Connect the outlet line peanut fitting to outlet line over frame. ^ Connect the fitting and loosely install the nut. 9. Install the outlet line through the floor. ^ Install the end of the tube with no tape through the floor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Condenser to Evaporator Line > Page 1803 10. Connect the peanut fitting to outlet line over frame. ^ Connect the fitting and loosely install the nut. 11. Tighten the five peanut fittings. 12. Install the tube brackets. 1. Position the bracket. 2. Install the nut. ^ Snap the tube into the bracket. NOTE: The bracket must be positioned equally between the white location marks on the tube. 13. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. 14. Connect the outlet tube to the auxiliary evaporator case tube. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Condenser to Evaporator Line > Page 1804 15. Install the grommet tube seal and retainer. NOTE: Insure that the tubes are entering through the center of the floor opening and that the retainer locating marks are positioned correctly. 16. Install the quarter trim access panel. 17. Evacuate and charge the A/C system. See: Heating and Air Conditioning/Service and Repair/Evacuation 18. Install the spare tire. Inlet Tube - (3/8 In) REMOVAL 1. Recover the refrigerant from the A/C system. See: Heating and Air Conditioning/Service and Repair/Refrigerant Recovery 2. Remove the quarter trim panel access cover. 3. Disconnect the inlet tube from the underbody line. 1. Remove the nut. 2. Remove the line. 4. Remove the auxiliary A/C lines grommet retainer. 1. Remove the bolts. 2. Remove the retainer. 5. Remove the spare tire. 6. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Condenser to Evaporator Line > Page 1805 7. Remove the four tube brackets. 1. Remove the nuts. 2. Remove the bracket by inserting a screw driver in the bracket slot and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the tubes. 8. Disconnect the inlet line peanut fitting. 1. Remove the nut. 2. Disconnect the line. 9. Cut the (3/8 in) inlet tube in four places. 10. Remove and discard the line. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Condenser to Evaporator Line > Page 1806 1. Install the inlet tube from the rear of the vehicle over the frame. 2. Connect the inlet tube to the front underbody A/C lines. 1. Connect the inlet tube. 2. Loosely install the nut. 3. Install the inlet tube over the frame. ^ Insert the end with orange tape first. 4. Connect the inlet tubes. 1. Connect the inlet tubes. 2. Loosely install the nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Condenser to Evaporator Line > Page 1807 5. Install the inlet tube. ^ Install the end with yellow tape between the frame and body. 6. Connect the inlet tubes. ^ Connect the fitting and loosely install the nut. 7. Install the inlet tube. ^ Install the end without tape through the floor. 8. Connect the inlet tubes. 1. Connect the line. 2. Loosely install the nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Condenser to Evaporator Line > Page 1808 9. Tighten the four peanut fittings. 10. Install the tube brackets. 1. Position the bracket. 2. Install the nut. ^ Snap the tube into the bracket. NOTE: The bracket must be positioned equally between the white location marks on the tube. 11. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. 12. Connect the inlet tube to the auxiliary evaporator case tube. 13. Install the grommet tube seal and retainer. NOTE: Insure that the tubes are entering through the center of the floor opening and that the retainer locating marks are positioned correctly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Condenser to Evaporator Line > Page 1809 14. Install the quarter trim access panel. 15. Evacuate and charge the A/C system. See: Heating and Air Conditioning/Service and Repair/Evacuation 16. Install the spare tire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Condenser to Evaporator Line > Page 1810 Hose/Line HVAC: Service and Repair Outlet Tube - Auxiliary A/C, Front Assembly REMOVAL 1. Recover the refrigerant from the system. See: Heating and Air Conditioning/Service and Repair/Refrigerant Recovery 2. Remove the RH front fender splash shield. 1. Remove the five screws. 2. Remove the three pushpins. 3. Remove the front fender splash shield. 3. Remove the three tube brackets. 1. Remove the nuts. 2. Remove the bracket by inserting a screw driver in the bracket slot and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the tubes. 4. Disconnect the auxiliary outlet tube from the condenser line. 1. Remove the nut. 2. Disconnect the tube. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Condenser to Evaporator Line > Page 1811 5. Disconnect the front auxiliary outlet line from the rear auxiliary tube. 1. Remove the nut. 2. Disconnect the tube. 6. Remove the front auxiliary outlet line. INSTALLATION 1. Install the front auxiliary outlet tube. 2. Connect the front auxiliary outlet line to the rear auxiliary line. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Condenser to Evaporator Line > Page 1812 3. Connect the front auxiliary outlet tube to the condenser line. 1. Connect the tube. 2. Install the nut. 4. Install the tube brackets. 1. Position the bracket. 2. Install the nut. ^ Snap the tube into the bracket. NOTE: The bracket must be positioned equally between the white location marks on the tube. 5. Install the front fender splash shield. 6. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. 7. Evacuate and charge the A/C system. See: Heating and Air Conditioning/Service and Repair/Evacuation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Page 1813 Hose/Line HVAC: Tools and Equipment Spring Lock Coupling Disconnect Tool Set Spring Lock Coupling Disconnect Tool (5/8 Inch) Spring Lock Coupling Spring Lock Coupling Heater Hose Disconnect Tool Heater Hose Disconnect Tool Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Page 1814 Heater Hose Disconnect Tool Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications TORQUE SPECIFICATIONS Power Steering Hose Fittings .................................................................................................................................................. 17-23 Nm (12.6-17 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Description and Operation Radiator Hose: Description and Operation The lower radiator hose: ^ Is equipped with a new style quick connect fitting at the radiator connection. ^ Can be disconnected and connected from the radiator without replacing the O-rings or the shrink band clamp. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Hoses (Lower) Radiator Hose: Service and Repair Radiator Hoses (Lower) REMOVAL 1. Drain the cooling system. 2. Remove inlet side of air cleaner assembly. 3. Disconnect the lower radiator hose from the water pump. 4. Disconnect the lower radiator hose from the radiator coolant recovery reservoir. 5. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 6. If equipped with engine oil cooler, disconnect the lower radiator hose connections from the oil cooler. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Hoses (Lower) > Page 1823 7. Disconnect the lower radiator hose from the radiator. a. Pry the locking tab up and out of the slot. b. Rotate the hose. c. Disconnect and remove the hose. INSTALLATION To install, reverse the removal procedure. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. The lower radiator hose does not require rotation for installation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Hoses (Lower) > Page 1824 Radiator Hose: Service and Repair Radiator Hoses (Upper) REMOVAL 1. Partially drain the cooling system. 2. Remove the upper radiator hose. a. Release the two hose clamps and slide away from the hose ends. b. Remove the upper radiator hose. INSTALLATION 1. Install the upper radiator hose. a. Position the upper radiator hose. b. Compress and position the hose clamps. NOTE: Ensure that the hose is seated in the upper hose support bracket. 2. Fill the cooling system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Hydraulic brake fluid color must conform with the requirements of Federal Motor Vehicle Safety Standard 116. Under this standard, brake fluids are visually different from other automotive fluids such as transmission, power steering and engine oil. High Performance DOT3 Brake Fluid Ford Specification ESA-M6C25-A Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement Technical Service Bulletin # 98B33 Date: 990401 Campaign - Coolant/Cylinder Head Replacement OWNER NOTIFICATION PROGRAM 98B33 Certain 1997 and 1998 Expedition, F-150 and 1998 Navigator vehicles equipped with 4.6L and 5.4L engines for inspection of coolant and, if necessary, replacement of engine cylinder heads ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Refund Codes ^ Attachment II ^ Labor Allowances ^ Parts Requirements ^ Attachment IIIA ^ A - Coolant Test Instructions ^ Attachment IIIB ^ B - Cylinder Head Replacement Instructions ^ Attachment IV ^ Copy of Lincoln Commitment Special Handling Procedure Letter ^ Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1837 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1838 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles on the enclosed list. PROMPTLY CORRECT ^ Affected vehicles on the enclosed list. ^ Other eligible vehicles which are brought to your dealership. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1839 DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with this special handling procedure. CLAIMS Enter claims using DWE. See ACESII Manual. To claim for the "Lincoln Commitment Special Handling", follow the instructions on Attachment IV. OWNER REFUNDS See ACESII Manual, Section 3 for submission procedures. For owner-paid repairs of cracked cylinder heads or damage directly related to cracked cylinder heads made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from servicing dealer), enter using DWE: RENTAL CARS If cylinder head replacement is necessary, Ford will pay for a loaner or rental vehicle except for fuel and insurance which will be at the owner's expense. Do not provide a rental vehicle while cylinder heads are on order. Rentals should be provided only while the vehicle is at the dealership for cylinder head replacement. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number of days vehicle was used in the Miscellaneous Expense area of the recall claim. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1840 COOLANT TESTER Coolant concentrate test kits will be sent at no charge 10 dealers with affected vehicles. Additional stock of testers is limited, but testers may be ordered from the Recall Hotline 1-800-325-5621. PARTS REQUIREMENTS Parts Ordering Information Cylinder head kits can be ordered by calling the Recall Hotline at 1-800-325-5621. The kits listed contain all parts necessary for cylinder head replacement except coolant, oil and oil filter: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1841 DEALER PRICE For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book CLAIMS PREPARATION Enter using DWE. Use code information shown below: ^ Program Code: 98B33 ^ Labor Operation: (see Labor Allowances) See the ACESII manual for detailed instructions. Attachment IIIA - A-Coolant Test Instructions SERVICE PROCEDURE 1. Open hood. 2. Remove coolant recovery bottle cap. 3. Run engine until normal operating temperature (thermostat open) is reached. 4. Insert supplied glycol tester (Thexton 106) into coolant recovery bottle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1842 5. Fill tester to level shown in Figure 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1843 ^ If five (5) or less discs float, refer to Figure 2, no service action is needed. Return vehicle to customer. ^ If all six (6) discs float, indicating "NOT SAFE" glycol condition, see Figure 2, call Recall Hotline at 1-800-325-5621 to order cylinder head kit. Perform cylinder head replacement, when kit arrives. Removal Removal 1. On air suspension equipped vehicles, turn air suspension switch, located in the RH kick panel area, to the OFF position. 2. Install memory saver, then disconnect battery negative cable. 3. Remove shield covering throttle body assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1844 4. Disconnect mass air flow (MAF) sensor electrical connector. Refer to Figure 1. 5. Disconnect intake air temperature (IAT) sensor electrical connector. Refer to Figure 1. 6. Remove air cleaner half and clean air tube as an assembly. See Figure 1. 7. Remove remaining half of air cleaner. 8. Disconnect accelerator cable, speed control cable and return spring from throttle body. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1845 9. Remove accelerator cable bracket from intake manifold, then unclip cables from clip on power steering reservoir bracket. See Figure 2. Position cable assembly aside. 10. On 4.6L engines, proceed as follows: ^ Disconnect vapor management valve (VMV) vacuum line at rear of throttle body adapter. Refer to Figure 3. ^ Disconnect vacuum tap on right side of throttle body adapter. Refer to Figure 3. ^ Disconnect PCV hose at rear of throttle body adapter. Refer to Figure 3. ^ Remove brake booster vacuum line retainer at EGR valve. Disconnect vacuum line at throttle body adapter. See Figure 3. Position line aside. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1846 ^ Disconnect vapor management valve (VMV) vacuum line. Refer to Figure 4. ^ Disconnect fuel pressure regulator vacuum line. Refer to Figure 4. ^ Disconnect EGR valve vacuum line. Refer to Figure 4. ^ Disconnect EVR solenoid vacuum line. See Figure 4. ^ Position vacuum harness away from engine. 11. On 5.4L engines, proceed as follows: ^ Remove power steering reservoir bracket retainers, then position reservoir assembly aside. See Figure 5. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1847 ^ Disconnect crankcase vent tube from left cam cover. Remove vent tube from vehicle. 12. Raise vehicle. 13. Disconnect EGR tube from exhaust manifold. 14. Disconnect oil pressure switch electrical connector. See Figure 6. 15. Disconnect crankshaft position (CKP) sensor electrical connector. See Figure 7. 16. On 4X2 models, disconnect A/C clutch electrical connector. 17. Drain coolant from radiator. NOTE: Do not remove right side cylinder block coolant drain plug. 18. Remove left side cylinder block coolant drain plug. Allow coolant to completely drain. 19. Install cylinder block coolant drain plug. Tighten plug to 16-24 Nm (12-17 lb-ft). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1848 20. Drain engine oil. Do not final tighten drain plug at this time, as it will be removed again. 21. Lower vehicle. NOTE: The best access to the A/C electrical connector is through the wheel well. 22. On 4X4 models, disconnect A/C clutch electrical connector. 23. Mark and disconnect DPFE transducer hoses from EGR tube. 24. Disconnect EGR tube from EGR valve, then remove EGR tube from vehicle. 25. On 4.6L engines, proceed as follows: ^ Remove power steering reservoir bracket retainers, then position reservoir assembly aside. See Figure 8. ^ Disconnect crankcase vent tube from left cam cover. Remove vent tube from vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1849 ^ Disconnect EVR solenoid electrical connector. Refer to Figure 9. ^ Disconnect Throttle Position (TP) sensor electrical connector. Refer to Figure 9. ^ Disconnect Idle Air Control (IAC) motor electrical connector. Refer to Figure 9. ^ Disconnect DPFE transducer electrical connector. See Figure 9. ^ Disconnect left side coil pack electrical connector. Refer to Figure 10. ^ Disconnect camshaft position (CMP) sensor electrical connector. Refer to Figure 10. ^ Disconnect left side radio interference suppressor electrical connector. See Figure 10. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1850 ^ Disconnect ignition wires from left side coil pack. ^ Remove left side coil pack from vehicle. ^ Unclip left side fuel charge harness from cam cover studs. Refer to Figure 11. ^ Unclip ignition wire separators from left cam cover studs. See Figure 11. ^ Disconnect ignition wires from left side spark plugs. Route ignition wires to front of engine. ^ Disconnect left side fuel injector electrical connectors. 26. On 5.4L engines, proceed as follows: ^ Disconnect Vapor Management Valve (VMV) vacuum line. Refer to Figure 12. ^ Disconnect fuel pressure regulator vacuum line. Refer to Figure 12. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1851 ^ Disconnect EGR valve vacuum line. Refer to Figure 12. ^ Disconnect EVR solenoid vacuum line. See Figure 12 ^ Disconnect vacuum tap on right side of throttle body adapter. Refer to Figure 13. ^ Position vacuum harness away from engine. ^ Disconnect VMV purge line at top of throttle body adapter. See Figure 13. ^ Disconnect brake booster vacuum line from throttle body adapter. ^ Remove brake booster vacuum line bracket from intake manifold. Position vacuum line assembly away from intake manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1852 ^ Disconnect Idle Air Control (IAC) motor electrical connector. See Figure 14. ^ Disconnect left side radio interference suppressor electrical connector. Refer to Figure 15. ^ Disconnect DPFE transducer electrical connector. Refer to Figure 15. ^ Disconnect EVR solenoid electrical connector. Refer to Figure 15. ^ Disconnect Throttle Position (TP) sensor electrical connector. Refer to Figure 15. ^ Disconnect Engine Coolant Temperature (ECT) sensor electrical connector. See Figure 15. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1853 ^ Disconnect camshaft position (CMP) sensor electrical connector. See Figure 16. ^ Disconnect ignition coil electrical connectors from left side of engine. Refer to Figure 17. ^ Disconnect fuel injector electrical connectors from left side of engine. See Figure 17. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1854 ^ Remove left side fuel charge harness from cam cover studs, then position harness away from cam cover. See Figure 18. ^ Remove left side ignition coils from vehicle. WARNING DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. WARNING FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. 27. Relieve fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on EFI/CFI fuel pressure gauge. ^ Remove fuel pressure gauge and reinstall schrader valve cap. 28. Disconnect fuel lines from fuel manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1855 29. Remove junction block splash shield. See Figure 19. 30. Disconnect positive leads from starter relay. Refer to Figure 20. 31. Unclip two (2) mega-fuses from bracket. Refer to Figure 20. 32. Disconnect two (2) 42-pin bulkhead electrical connectors. Refer to Figure 20. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1856 33. Remove both bulkhead electrical connector halves from bracket. See Figure 20. 34. Disconnect 16-pin electrical connector. Refer to Figure 21. 35. Disconnect single-pin electrical connector. Refer to Figure 21. 36. Remove junction block bracket. See Figure 21. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1857 37. Remove heater supply hose from vehicle. Refer to Figure 22. 38. Disconnect heater return hose from heater core fitting. Then position hose away from right cam cover. Refer to Figure 22. 39. Remove ground strap to bulkhead retaining bolt, then unwrap ground strap from fuel manifold. See Figure 22. 40. Remove PCV valve and line from vehicle. 41. On 4.6L engines, proceed as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1858 ^ Disconnect right side coil pack electrical connector. Refer to Figure 23. ^ Disconnect right side radio interference suppressor electrical connector. Refer to Figure 23. ^ Disconnect ignition wires from right side coil pack. See Figure 23. ^ Remove right side coil pack from vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1859 ^ Unclip right side fuel charge harness from cam cover studs. Refer to Figure 24. ^ Unclip ignition wire separators from right cam cover studs. See Figure 24. ^ Disconnect ignition wires from right side spark plugs. Route ignition wires to front of engine. ^ Disconnect right side fuel injector electrical connectors. ^ Disconnect Engine Coolant Temperature (ECT) sensor electrical connector. Refer to Figure 25. ^ Disconnect water temperature sender electrical connector. Refer to Figure 25. ^ Remove tie strap retaining alternator wiring harness to fuel manifold. See Figure 25. 42. On 5.4L engines, proceed as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1860 ^ Disconnect right side radio interference suppressor. See Figure 26. ^ Disconnect ignition coil electrical connectors from right side of engine. Refer to Figure 27. ^ Disconnect fuel injector electrical connectors from right side of engine. See Figure 27. ^ Remove right side fuel charge harness from cam cover studs, then position harness away from cam cover. ^ Remove right side ignition coils from vehicle. ^ Remove tie strap retaining alternator wiring harness to fuel manifold. 43. Disconnect upper radiator hose from thermostat housing. 44. Remove drive belt. 45. Remove alternator and mounting bracket as an assembly. The ignition wires and the alternator wiring harness will also be removed with the alternator assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1861 46. Disconnect cylinder head temperature (CHT) sensor electrical connector. Refer to Figure 28. 47. Disconnect tuning valve electrical connector. See Figure 28. 48. Remove the intake manifold retaining bolts. See Figure 29. 49. Remove intake manifold from vehicle. 50. Remove and discard intake manifold gaskets. NOTE: On 5.4L engine, cam cover bolts cannot be separated from cam cover. NOTE: Be careful not to damage cam cover gaskets, as they will be reused. Remove both camshaft covers. 51. Remove both camshaft covers. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1862 52. Disconnect heater return hose from coolant tube, then remove heater hose from vehicle. Refer to Figure 30. 53. Remove retainers securing routing bracket to rear of right-hand cylinder head, then remove routing bracket and ground strap. Refer to Figure 30. 54. Remove coolant tube retainers securing coolant tube to rear of right hand cylinder head, then remove coolant tube. See Figure 30. 55. Remove jack handle from radiator air deflector. 56. Remove air deflector on top of radiator. 57. Disconnect coolant recovery hose from radiator. 58. Using Fan Clutch Holding Tool T84T-6312-C and Fan Clutch Wrench T93T-6312-B, remove cooling fan and clutch assembly. 59. Remove cooling fan shroud. 60. On automatic transmission models, disconnect transmission lines from radiator. 61. Disconnect lower radiator hose from radiator. 62. Remove radiator support brackets, then the radiator. 63. Remove water pump pulley, then the water pump. 64. On 4.6L and 5.4L Windsor engines, proceed as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1863 ^ Remove two (2) upper power steering pump retaining bolts. Refer to Figure 31. ^ Raise vehicle. ^ Remove one (1) lower power steering pump retaining bolt, then position power steering pump away from front engine cover. See Figure 31. 65. On Romeo engines, proceed as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1864 ^ Remove two (2) upper power steering pump retaining bolts. See Figure 32. ^ Raise vehicle. NOTE: One of the following bolts cannot be completely removed from the power steering pump due to clearance with the power steering line. ^ Remove two (2) lower power steering pump retaining bolts, then position power steering pump away from front engine cover. See Figure 33. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1865 66. Remove four (4) front oil pan bolts. See Figure 34. 67. Lower vehicle. 68. Using Crankshaft Damper Remover T58P-6316-D, remove crankshaft pulley. 69. Using Front Cover Seal Remover T74P-6700-A, remove engine front cover oil seal. 70. Remove idler pulley from right side of engine front cover. This pulley blocks a front cover bolt. 71. Remove engine front cover retainers. See Figure 35. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1866 72. Remove engine front cover from engine. See Figure 36. 73. Remove crankshaft sensor ring. 74. Using Crankshaft Holding Tool T93P-6303-A, rotate crankshaft until crankshaft keyway points to the 12 o'clock position. See Figure 37. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1867 75. Install Camshaft Holding Tool T96T-6256-B, on each camshaft. See Figure 38 for holding tool placement. 76. Remove both timing chain tensioners. See Figure 39. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1868 77. Remove both timing chain tensioner guides. See Figure 40. 78. Lift right-hand timing chain off camshaft sprocket, then slide timing chain and crankshaft sprocket off crankshaft. Refer to Figure 41. 79. Lift left-hand timing chain off camshaft sprocket, then slide timing chain and crankshaft sprocket off crankshaft. See Figure 41. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1869 80. Remove both timing chain guides. See Figures 42 and 43. NOTE: Removal of this wheel opening molding screw is necessary to access all screws for the fender splash shield. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1870 81. On 4X4 models, remove one (1) screw shown in Figure 44, from both wheel opening moldings. 82. Remove both front fender splash shields. See Figure 45. 83. Raise vehicle. 84. Disconnect exhaust Y-pipe from exhaust manifolds. 85. Slightly lower vehicle. Exhaust manifold retainers will be accessed through the wheel well opening. 86. Remove left side exhaust manifold and gasket. Retain gasket for reuse. Replace gasket if damaged. 87. Loosen engine oil indicator tube; then turn tube away from cylinder head. Removal of indicator tube is not necessary. 88. Remove right side exhaust manifold and gasket. Retain gasket for reuse. Replace gasket if damaged. 89. Remove retainer securing transmission indicator tube to right cylinder head if equipped. NOTE: Cylinder head bolts that are under the camshaft holding tools cannot be completely removed from the head due to clearance with the holding tool. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1871 Completely loosen these bolts. 90. Remove both cylinder heads. See Figure 46. Discard all cylinder head bolts. 91. Remove and discard both cylinder head gaskets. 92. On Romeo engines, proceed as follows: ^ Remove spark plugs from right cylinder head. ^ Remove camshaft sprocket from right side camshaft. ^ Remove Camshaft Holding Tool from right side camshaft. ^ Install camshaft sprocket on new right side camshaft. Do not final tighten retaining bolt at this time. ^ Remove spark plugs from left cylinder head. ^ Remove camshaft sprocket from left side camshaft. ^ Remove Camshaft Holding Tool from left side camshaft. ^ Install camshaft sprocket on new left side camshaft. Do not final tighten retaining bolt at this time. ^ Remove power steering reservoir bracket and CHT sensor from left cylinder head. 93. On 4.6L and 5.4L Windsor engines, proceed as follows: ^ Remove Camshaft Holding Tools from both camshafts. ^ Remove power steering reservoir bracket and Cylinder Head Temperature sensor from left cylinder head. ^ Remove all eight (8) spark plugs from cylinder heads. 94. Clean the following gasket surfaces: ^ Cylinder block to cylinder head. ^ Engine front cover. ^ Water pump. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1872 ^ Intake manifold. ^ Both cam covers. Installation 1. On all cylinder heads, install one (1) pipe plug into the rear of each cylinder head in locations shown in Figure 47. 2. On 4.6L Romeo engines, install one (1) pipe plug into the front of each cylinder head in locations shown in Figure 48. 3. Install CHT sensor to left cylinder head. Tighten sensor to 24-28 Nm (17-20 lb-ft). 4. Install power steering bracket to left cylinder head. 5. Install all spark plugs (both sides). Tighten plugs to 9-20 Nm (81-178 lb-in). 6. Install right cylinder head gasket. 7. Install right cylinder head. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1873 8. Tighten right cylinder head bolts in sequence shown in Figure 49 in the following three (3) stages: ^ Stage 1: 37-43 Nm (27-32 lb-ft). ^ Stage 2: Rotate 85-95 degrees. ^ Stage 3: Rotate 85-95 degrees. 9. Lubricate all camshaft journals. 10. Install left cylinder head gasket. 11. Install left cylinder head. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1874 12. Tighten left cylinder head bolts in sequence shown in Figure 50 in the following three (3) stages: ^ Stage 1: 37-43 Nm (27-32 lb-ft). ^ Stage 2: Rotate 85-95 degrees. ^ Stage 3: Rotate 85-95 degrees. 13. Lubricate all camshaft journals. 14. Raise vehicle. 15. Install transmission indicator tube retainer to right cylinder head if equipped. Tighten retainer to 18-23 Nm (14-16 lb-ft). 16. Install right side exhaust manifold gasket. NOTE: Due to clearance, the exhaust system Y-pipe mounting flange cannot be positioned on the exhaust manifold outlet after the exhaust manifold is installed on the cylinder head. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1875 17. Install right side exhaust manifold and gasket. Align exhaust system Y-pipe mounting flange with the studs in the exhaust manifold outlet before completely installing the exhaust manifold on the cylinder block. Tighten right side exhaust manifold retainers in sequence shown in Figure 51 to 18-22 Nm (13-16 lb-ft). 18. Position engine oil indicator tube in installed position. 19. Install left side exhaust manifold and gasket. Tighten retainers in sequence shown in Figure 52 to 18-22 Nm (13-16 lb-ft). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1876 20. Remove oil pan drain plug. Completely drain any fluid (oil, coolant) from oil pan. Reinstall drain plug, tightening to 11-16 Nm (98-143 lb-in). 21. Replace oil filter. 22. Install exhaust system Y-pipe to exhaust manifolds. Tighten retainers to 34-46 Nm (25-34 lb-ft). 23. Lower vehicle. 24. Install both fender splash shields. Tighten retainers to 10-13 Nm (89-115 lb-in). 25. On 4X4 models, install one screw removed from both wheel opening moldings. 26. On Romeo engines, proceed as follows: ^ Using socket on camshaft sprocket bolt, rotate left camshaft until timing mark is in 12 o'clock position. Refer to Figure 53. ^ Using socket on camshaft sprocket bolt, rotate right camshaft until timing mark is in 11 o'clock position. Refer to Figure 53. 27. On 4.6L and 5.4L Windsor engines, proceed as follows: ^ Using Camshaft Positioning Tool T96T-6256-AR, rotate left camshaft until timing mark is in 12 o'clock position. Refer to Figure 53. ^ Using Camshaft Positioning Tool T96T-6256-AR, rotate right camshaft until timing mark is in 11 o'clock position. See Figure 53. ^ Install Camshaft Holding Tool T96T-6256-B on each camshaft. 28. On Romeo engines, tighten both camshaft sprocket bolts to 110-130 Nm (81-95 lb-ft). CAUTION Rotate the crankshaft counterclockwise only. Do not rotate past position shown or severe piston and/or valve damage can occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1877 29. Rotate crankshaft using Crankshaft Holding Tool T93P-6303-A. See Figure 54. Fully install holding tool. This will position crankshaft keyway to about 10:30 position. 30. Remove Crankshaft Holding Tool. 31. Compress timing chain tensioner plunger as follows: CAUTION Do not compress the ratchet assembly. This will damage the ratchet assembly. CAUTION Use protective vocers over jaws of vise to prevent damage to tensioner. ^ Compress tensioner plunger using edge of vise. See Figure 55. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1878 ^ Using small screwdriver or pick, push back and hold ratchet mechanism. See Figure 56. ^ While holding ratchet mechanism, push ratchet arm back into tensioner housing. See Figure 57. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1879 ^ Install paper clip into hole in tensioner housing. This will hold ratchet assembly and plunger in during installation. See Figure 58. ^ Remove tensioner from vise. ^ Repeat procedure for second tensioner. 32. If copper links are not visible, mark one (1) link on each end of the timing chain. One link will be an inside link. Use these marks as timing marks. See Figure 59. Repeal this step for other timing chain, if necessary. 33. Install right side timing chain guide. Tighten retainers to 8-12 Nm (71-106 lb-in). 34. Install left side timing chain guide. Tighten retainers to 8-12 Nm (71-106 lb-in). 35. Install timing chains and sprockets as follows: ^ Position left side crankshaft sprocket in left side timing chain. Make sure crankshaft sprocket hub is facing outward. Align mark on timing chain with corresponding dot on crankshaft sprocket. ^ Slide left side sprocket and chain on crankshaft. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1880 ^ Position left side timing chain over camshaft sprocket, aligning timing mark on chain with dot on camshaft sprocket. If necessary, loosen camshaft holding tool and adjust camshaft sprocket to obtain timing mark alignment. Tighten camshaft holding tool after timing marks are aligned. ^ Position right side crankshaft sprocket in right side timing chain. Make sure crankshaft sprocket hub is facing inward. Align mark on timing chain with corresponding dot on crankshaft sprocket. ^ Slide right side sprocket and chain on crankshaft. ^ Position right side timing chain over camshaft sprocket, aligning timing mark on chain with dot on camshaft sprocket. If necessary, loosen camshaft holding tool and adjust camshaft sprocket to obtain timing mark alignment. Tighten camshaft holding tool after timing marks are aligned. ^ Make sure marks on timing chain are lined up with corresponding dots on crankshaft and camshaft sprockets. See Figure 60. ^ Make sure right side crankshaft sprocket is in front of left side crankshaft sprocket with hubs facing each other. See Figure 61. 36. Install right and left timing chain tensioner guides. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1881 37. Install right and left timing chain tensioners. Tighten retainers to 20-30 Nm (15-20 lb-ft). 38. Remove paper clips from both timing chain tensioners. 39. Remove both camshaft holding tools. 40. Install crankshaft sensor ring. 41. Install engine front cover as follows: NOTE: The engine front cover must be installed within four (4) minutes after applying silicone. Apply Silicone Gasket and Sealant F6AZ-1 9562-AA or equivalent, along head to block surface and oil pan to block surface. See Figure 62. ^ Using new gasket, install engine front cover. Align cover with cylinder block dowel. ^ Loosely install engine front cover bolts and stud bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1882 ^ Tighten first five (5) engine front cover bolts in sequence shown in Figure 63, to 20-30 Nm (15-22 lb-ft). ^ Tighten remaining ten (10) engine front cover bolts in sequence shown in Figure 64. On Romeo engines, tighten bolts to 20-30 Nm (15-22 lb-ft). On 4.6L and 5.4L Windsor engines, tighten bolts to 40-55 Nm (29-40 lb-ft). 42. Install right side idler pulley. Tighten retainer to 20-30 Nm (15-22 lb-ft). 43. Using clean engine oil, lubricate engine front cover oil seal inner lip. 44. Using Crankshaft Seal Replacer/Aligner T88T-6701-A, install front cover oil seal. 45. Install crankshaft pulley as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1883 NOTE: The crankshaft pulley must be installed within four (4) minutes after applying silicone. Apply Silicone Gasket and Sealant F6AZ-1 9562-AA or equivalent, to woodruff key slot on crankshaft pulley. See Figure 65. ^ Using Crankshaft Damper Replacer T74P-6316-B, install crankshaft pulley. ^ Loosely install crankshaft pulley bolt. ^ Tighten crankshaft pulley bolt to 90 Nm (66 lb-ft). ^ Loosen crankshaft pulley bolt one (1) full turn. ^ Tighten crankshaft pulley bolt to 47-53 Nm (34-39 lb-ft). ^ Tighten crankshaft pulley bolt an additional 85-90 degrees (1/4 turn). 46. On Romeo engines, proceed as follows: ^ Position power steering pump in installed position. Tighten two (2) upper bolts to 20-30 Nm (15-22 lb-ft). ^ Raise vehicle. ^ Install two (2) power steering pump lower retaining bolts. Tighten bolt to 20-30 Nm (15-22 lb-ft). 47. On 4.6L and 5.4L Windsor engines, proceed as follows: ^ Position power steering pump in installed position. Tighten two (2) upper bolts to 20-30 Nm (15-22 lb-ft). ^ Raise vehicle. ^ Install power steering pump lower retaining bolt. Tighten bolt to 20-30 Nm (15-22 lb-ft). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1884 48. Loosely install four (4) front oil pan bolts. Tighten bolts in sequence shown in Figure 66, in the following two (2) stages: ^ Stage 1: 20 Nm (15 lb-ft). ^ Stage 2: Rotate an additional 60 degrees. 49. Lower vehicle. 50. Using coolant, lubricate new water pump O-ring seal. Install seal on water pump. 51. Install water pump. Tighten retainers in sequence shown in Figure 67, to 20-30 Nm (15-22 lb-ft). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1885 52. Install water pump pulley. Tighten retainers in sequence shown in Figure 68, to 20-30 Nm (15-22 lb-ft). 53. Install radiator. Make sure radiator is sitting on mounting insulators. 54. Install radiator supports. Tighten retainers to 25-35 Nm (18-26 lb-ft). 55. Connect lower radiator hose to radiator. 56. On automatic transmission models, connect transmission cooler lines to radiator. Tighten lines to 16-24 Nm (12-18 lb-ft). 57. Install cooling fan shroud. Tighten retainer 108-10 Nm (71-89 lb-in). 58. Using Fan Clutch Holding Tool T84T-6312-C and Fan Clutch Wrench T93T-6312-B, install cooling fan and clutch assembly. 59. Connect coolant recovery hose to radiator. 60. Install air deflector on top of radiator. 61. Install jack handle on radiator air deflector. 62. Using clean coolant, lubricate coolant tube O-ring seal. Install coolant tube. Tighten retainers on rear of right cylinder head to 40-55 Nm (29-40 lb-ft). NOTE: Make sure left side fuel charge harness is between routing bracket and cylinder head. 63. Install routing bracket and ground strap to rear of right cylinder head. Tighten retainers to 9-12 Nm (80-107 lb-in). 64. Install heater return hose to coolant tube. 65. Install cam cover gaskets on both cam covers. NOTE: The cam cover must be installed within four (4) minutes after applying silicone. 66. Apply Silicone Gasket and Sealant F6AZ-1 9562-AA or equivalent, to the two (2) places where the engine front cover meets the cylinder head. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1886 67. Install right side cam cover. Tighten retainers in sequences shown in Figures 69 and 70, to 8-12 Nm (71-107 lb-in). NOTE: The cam cover must be installed within four (4) minutes after applying silicone. 68. Apply Silicone Gasket and Sealant F6AZ-19562-AA or equivalent, to the two (2) places where the engine front cover meets the cylinder head. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1887 69. Install left side cam cover. Tighten retainers in sequences shown in Figures 71 and 72, to 8-12 Nm (71-107 lb-in). 70. Install new intake manifold gaskets. 71. Install intake manifold (including thermostat housing). Tighten bolts in sequence shown in Figure 73, in the following two (2) stages: ^ Stage 1: 2 Nm (18 lb-in). ^ Stage 2: 20-30 Nm (15-22 lb-ft). 72. Loosely position left side fuel charge harness on cam cover. 73. Connect tuning valve electrical connector. 74. Connect CHT sensor electrical connector. 75. Install alternator assembly. Tighten front alternator bolts to 21-28 Nm (15-21 lb-ft). Tighten alternator bracket bolts to 9-12 Nm (80-106 lb-in). 76. Install drive belt. 77. Using tie strap, retain alternator wiring harness to fuel manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1888 78. On 4.6L engines, proceed as follows: ^ Loosely position right side fuel charge harness on cam cover. ^ Connect water temperature sensor electrical connector. ^ Connect ECT sensor electrical connector. ^ Connect right side ignition wires to spark plugs. ^ Clip ignition wire separators to right cam cover. ^ Connect right side fuel injector electrical connectors. ^ Clip right side fuel charge harness to cam cover. ^ Install right side ignition coil. Tighten retainers to 20-30 Nm (15-22 lb-ft). ^ Connect ignition wires to right side coil. ^ Connect right side radio interference suppressor electrical connector. ^ Connect right side coil pack electrical connector. 79. On 5.4L engines, proceed as follows: ^ Install right side ignition coils. Tighten retainers to 5-7 Nm (44-62 lb-in). ^ Position right side fuel charge harness on cam cover studs. ^ Connect right side fuel injector electrical connectors. ^ Connect right side ignition coil electrical connectors. ^ Connect right side radio interference suppressor. 80. Install PCV valve and line assembly. 81. Connect ground strap to bulkhead. 82. Connect heater return hose to heater core. 83. Install heater supply hose. 84. Install junction block bracket. Tighten retainers securely. 85. Connect single-pin electrical connector. 86. Connect 16-pin electrical connector. 87. Install both 42-pin bulkhead electrical connector halves to junction block bracket. 88. Connect both 42-pin bulkhead electrical connectors. Tighten retainers to 4-5 Nm (35-44 lb-in). 89. Clip two (2) mega-fuses to junction block bracket. 90. Connect positive leads to starter relay. 91. Install junction block bracket splash shield. 92. Connect fuel lines to fuel manifold. 93. On 4.6L engines, proceed as follows: ^ Connect left side ignition wires to spark plugs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1889 ^ Clip ignition wire separators to left cam cover. ^ Connect left side fuel injector electrical connectors. ^ Clip left side fuel charge harness to cam cover. ^ Install left side ignition coil. Tighten retainers to 20-30 Nm (15-22 lb-ft). ^ Connect ignition wires to left side coil. ^ Connect left side radio interference suppressor electrical connector. ^ Connect CMP electrical connector. ^ Connect left side coil pack electrical connector. ^ Connect DPFE transducer electrical connector. ^ Connect IAC motor electrical connector. ^ Connect TP sensor electrical connector. ^ Connect EVR solenoid electrical connector. ^ Connect crankcase vent tube to left cam cover. ^ Position power steering reservoir and bracket in installed position. Tighten upper retainers to 8-12 Nm (71-107 lb-in). Tighten lower retainers to 35-45 Nm (26-33 lb-ft). 94. On 5.4L engines, proceed as follows: ^ Install left side ignition coils. Tighten retainers to 5-7 Nm (44-62 lb-in). ^ Connect left side fuel injector electrical connectors. ^ Connect left side ignition coil electrical connectors. ^ Connect ECT sensor electrical connector. ^ Connect TP sensor electrical connector. ^ Connect EVR solenoid electrical connector. ^ Connect DPFE transducer electrical connector. ^ Connect left side radio interference suppressor electrical connector. ^ Connect IAC motor electrical connector. ^ Connect brake booster vacuum line to throttle body adapter, then install brake booster vacuum line bracket to intake manifold. ^ Connect VMV purge line to top of throttle body adapter. ^ Position vacuum harness on top of motor. ^ Connect vacuum tap to right side of throttle body adapter. ^ Connect EVR solenoid vacuum line. ^ Connect EGR valve vacuum line. ^ Connect fuel pressure regulator vacuum line. ^ Connect vapor management valve vacuum line. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1890 95. Connect EGR tube to EGR valve. Hand-tighten fitting at this time. 96. Connect DPFE transducer hoses to EGR tube. 97. On 4X4 models, connect A/C clutch electrical connector. 98. Raise vehicle. 99. Connect EGR tube to exhaust manifold. Tighten fitting to 35-45 Nm (26-33 lb-ft). 100. On 4X2 models, connect A/C clutch electrical connector. 101. Connect CKP sensor electrical connector. 102. Connect oil pressure switch electrical connector. 103. Lower vehicle. 104. Final tighten EGR tube to valve to 35-45 Nm (26-33 lb-ft). 105. On 4.6L engines, proceed as follows: ^ Loosely position vacuum harness over engine. ^ Connect EVR solenoid vacuum line. ^ Connect EGR valve vacuum line. ^ Connect fuel pressure regulator vacuum line. ^ Connect vapor management valve vacuum line. ^ Position brake booster vacuum line in installed position. Connect line to tap on throttle body adapter. Tighten line retainer at EGR valve to 8-12 Nm (71-106 lb-in). ^ Connect vacuum tap on right side of throttle body adapter. ^ Connect VMV vacuum line at rear of throttle body adapter. 106. On 5.4L engines, proceed as follows: ^ Connect crankcase vent tube to left cam cover. ^ Position power steering reservoir and bracket in installed position. Tighten upper retainers to 8-12 Nm (71-107 lb-in). Tighten lower retainers to 35-45 Nm (26-33 lb-ft). 107. Position accelerator/speed control cables on top of engine. Secure cables to clip on power steering reservoir. 108. Install accelerator cable bracket to intake manifold. Tighten retainer to 6-8 Nm (53-71 lb-in). 109. Connect accelerator cable, speed control cable and return spring to throttle body. 110. Connect upper radiator hose to thermostat housing. 111. Install rear half of air cleaner. 112. Install front half of air cleaner and clean air lube. 113. Connect IAT and MAF electrical connectors. 114. Install throttle body shield. 115. Connect battery negative cable. 116. Remove memory saver. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1891 117. Fill engine with new engine oil. 118. Fill cooling system as follows: ^ Add 50/50 coolant mixture to radiator coolant recovery reservoir. ^ Install radiator cap. ^ Move temperature blend selector to full warm position. ^ Run engine until it reaches operating temperature. ^ Add 50/50 coolant mixture to radiator coolant recovery reservoir until the coolant level is between the "COOLANT FILL LEVEL" marks. ^ Turn off engine and allow cooling system to cool. ^ Repeat bulleted steps until radiator coolant recovery reservoir level remains in between fill level marks when engine is cool. 119. On air suspension equipped models, turn air suspension switch to ON position. 120. Check engine for proper operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1892 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1893 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1894 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1895 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1896 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 01-23-6 > Nov > 01 > Engine Coolant - Propylene Glycol Recommendations Coolant: All Technical Service Bulletins Engine Coolant - Propylene Glycol Recommendations Article No. 01-23-6 11/26/01 ^ ENGINE COOLANT - PROPYLENE GLYCOL - FORD MOTOR COMPANY POSITION ON ENGINE COOLANTS MADE FROM PROPYLENE GLYCOL ^ ENGINE COOLANT - PROPYLENE GLYCOL-BASED - FORD MOTOR COMPANY POSITION ON PROPYLENE GLYCOL-BASED ENGINE COOLANTS FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2002 FOCUS 2002 THUNDERBIRD 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT 2000-2002 F-650, F-750 LINCOLN: 1989-1992 MARK VII 1989-2002 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1989-1994 TOPAZ 1989-1997 COUGAR 1989-2002 GRAND MARQUIS, SABLE 1991-1994 CAPRI 1991-1999 TRACER 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER MERKUR: 1989 SCORPIO, XR4TI This article is being republished in its entirety to update the model year coverage. ISSUE This TSB article describes Ford Motor Company's position on the use of propylene glycol-based engine coolants. ACTION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 01-23-6 > Nov > 01 > Engine Coolant - Propylene Glycol Recommendations > Page 1902 Ford Motor Company does not recommend nor endorse the use of engine coolants made with propylene glycol in Ford vehicles. Ford Motor Company currently recommends the use of ethylene glycol-based engine coolants. Published information suggests that engine coolants made with propylene glycol may provide engine cooling performance equivalent to engine coolants made with ethylene glycol. However, different brands of engine coolant provide varying corrosion protection for the cooling system. Ford does not have performance data for the multitude of engine coolants available in the aftermarket and therefore cannot recommend the use of any coolant except those sold by Ford Customer Service Division. Consult the vehicle's Owner's Guide to determine the appropriate Ford Customer Service Division coolant for the vehicle. Furthermore, claims of toxicological and environmental advantages of propylene glycol over ethylene glycol may be misleading. When significant new information is developed, Ford will review this policy. Ford Motor Company specifications recommend that vehicles be maintained using certain ethylene glycol-based engine coolants. Those specifications do not refer to engine coolants made with propylene glycol. Although the Ford New Vehicle Limited Warranty is not automatically voided upon the use of a coolant made with propylene glycol, if such use results in damage to the vehicle or its components, the cost of repairing the damage would not be covered by the Ford New Vehicle Limited Warranty. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-16-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement Technical Service Bulletin # 98B33 Date: 990401 Campaign - Coolant/Cylinder Head Replacement OWNER NOTIFICATION PROGRAM 98B33 Certain 1997 and 1998 Expedition, F-150 and 1998 Navigator vehicles equipped with 4.6L and 5.4L engines for inspection of coolant and, if necessary, replacement of engine cylinder heads ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Refund Codes ^ Attachment II ^ Labor Allowances ^ Parts Requirements ^ Attachment IIIA ^ A - Coolant Test Instructions ^ Attachment IIIB ^ B - Cylinder Head Replacement Instructions ^ Attachment IV ^ Copy of Lincoln Commitment Special Handling Procedure Letter ^ Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1907 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1908 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles on the enclosed list. PROMPTLY CORRECT ^ Affected vehicles on the enclosed list. ^ Other eligible vehicles which are brought to your dealership. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1909 DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with this special handling procedure. CLAIMS Enter claims using DWE. See ACESII Manual. To claim for the "Lincoln Commitment Special Handling", follow the instructions on Attachment IV. OWNER REFUNDS See ACESII Manual, Section 3 for submission procedures. For owner-paid repairs of cracked cylinder heads or damage directly related to cracked cylinder heads made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from servicing dealer), enter using DWE: RENTAL CARS If cylinder head replacement is necessary, Ford will pay for a loaner or rental vehicle except for fuel and insurance which will be at the owner's expense. Do not provide a rental vehicle while cylinder heads are on order. Rentals should be provided only while the vehicle is at the dealership for cylinder head replacement. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number of days vehicle was used in the Miscellaneous Expense area of the recall claim. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1910 COOLANT TESTER Coolant concentrate test kits will be sent at no charge 10 dealers with affected vehicles. Additional stock of testers is limited, but testers may be ordered from the Recall Hotline 1-800-325-5621. PARTS REQUIREMENTS Parts Ordering Information Cylinder head kits can be ordered by calling the Recall Hotline at 1-800-325-5621. The kits listed contain all parts necessary for cylinder head replacement except coolant, oil and oil filter: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1911 DEALER PRICE For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book CLAIMS PREPARATION Enter using DWE. Use code information shown below: ^ Program Code: 98B33 ^ Labor Operation: (see Labor Allowances) See the ACESII manual for detailed instructions. Attachment IIIA - A-Coolant Test Instructions SERVICE PROCEDURE 1. Open hood. 2. Remove coolant recovery bottle cap. 3. Run engine until normal operating temperature (thermostat open) is reached. 4. Insert supplied glycol tester (Thexton 106) into coolant recovery bottle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1912 5. Fill tester to level shown in Figure 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1913 ^ If five (5) or less discs float, refer to Figure 2, no service action is needed. Return vehicle to customer. ^ If all six (6) discs float, indicating "NOT SAFE" glycol condition, see Figure 2, call Recall Hotline at 1-800-325-5621 to order cylinder head kit. Perform cylinder head replacement, when kit arrives. Removal Removal 1. On air suspension equipped vehicles, turn air suspension switch, located in the RH kick panel area, to the OFF position. 2. Install memory saver, then disconnect battery negative cable. 3. Remove shield covering throttle body assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1914 4. Disconnect mass air flow (MAF) sensor electrical connector. Refer to Figure 1. 5. Disconnect intake air temperature (IAT) sensor electrical connector. Refer to Figure 1. 6. Remove air cleaner half and clean air tube as an assembly. See Figure 1. 7. Remove remaining half of air cleaner. 8. Disconnect accelerator cable, speed control cable and return spring from throttle body. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1915 9. Remove accelerator cable bracket from intake manifold, then unclip cables from clip on power steering reservoir bracket. See Figure 2. Position cable assembly aside. 10. On 4.6L engines, proceed as follows: ^ Disconnect vapor management valve (VMV) vacuum line at rear of throttle body adapter. Refer to Figure 3. ^ Disconnect vacuum tap on right side of throttle body adapter. Refer to Figure 3. ^ Disconnect PCV hose at rear of throttle body adapter. Refer to Figure 3. ^ Remove brake booster vacuum line retainer at EGR valve. Disconnect vacuum line at throttle body adapter. See Figure 3. Position line aside. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1916 ^ Disconnect vapor management valve (VMV) vacuum line. Refer to Figure 4. ^ Disconnect fuel pressure regulator vacuum line. Refer to Figure 4. ^ Disconnect EGR valve vacuum line. Refer to Figure 4. ^ Disconnect EVR solenoid vacuum line. See Figure 4. ^ Position vacuum harness away from engine. 11. On 5.4L engines, proceed as follows: ^ Remove power steering reservoir bracket retainers, then position reservoir assembly aside. See Figure 5. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1917 ^ Disconnect crankcase vent tube from left cam cover. Remove vent tube from vehicle. 12. Raise vehicle. 13. Disconnect EGR tube from exhaust manifold. 14. Disconnect oil pressure switch electrical connector. See Figure 6. 15. Disconnect crankshaft position (CKP) sensor electrical connector. See Figure 7. 16. On 4X2 models, disconnect A/C clutch electrical connector. 17. Drain coolant from radiator. NOTE: Do not remove right side cylinder block coolant drain plug. 18. Remove left side cylinder block coolant drain plug. Allow coolant to completely drain. 19. Install cylinder block coolant drain plug. Tighten plug to 16-24 Nm (12-17 lb-ft). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1918 20. Drain engine oil. Do not final tighten drain plug at this time, as it will be removed again. 21. Lower vehicle. NOTE: The best access to the A/C electrical connector is through the wheel well. 22. On 4X4 models, disconnect A/C clutch electrical connector. 23. Mark and disconnect DPFE transducer hoses from EGR tube. 24. Disconnect EGR tube from EGR valve, then remove EGR tube from vehicle. 25. On 4.6L engines, proceed as follows: ^ Remove power steering reservoir bracket retainers, then position reservoir assembly aside. See Figure 8. ^ Disconnect crankcase vent tube from left cam cover. Remove vent tube from vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1919 ^ Disconnect EVR solenoid electrical connector. Refer to Figure 9. ^ Disconnect Throttle Position (TP) sensor electrical connector. Refer to Figure 9. ^ Disconnect Idle Air Control (IAC) motor electrical connector. Refer to Figure 9. ^ Disconnect DPFE transducer electrical connector. See Figure 9. ^ Disconnect left side coil pack electrical connector. Refer to Figure 10. ^ Disconnect camshaft position (CMP) sensor electrical connector. Refer to Figure 10. ^ Disconnect left side radio interference suppressor electrical connector. See Figure 10. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1920 ^ Disconnect ignition wires from left side coil pack. ^ Remove left side coil pack from vehicle. ^ Unclip left side fuel charge harness from cam cover studs. Refer to Figure 11. ^ Unclip ignition wire separators from left cam cover studs. See Figure 11. ^ Disconnect ignition wires from left side spark plugs. Route ignition wires to front of engine. ^ Disconnect left side fuel injector electrical connectors. 26. On 5.4L engines, proceed as follows: ^ Disconnect Vapor Management Valve (VMV) vacuum line. Refer to Figure 12. ^ Disconnect fuel pressure regulator vacuum line. Refer to Figure 12. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1921 ^ Disconnect EGR valve vacuum line. Refer to Figure 12. ^ Disconnect EVR solenoid vacuum line. See Figure 12 ^ Disconnect vacuum tap on right side of throttle body adapter. Refer to Figure 13. ^ Position vacuum harness away from engine. ^ Disconnect VMV purge line at top of throttle body adapter. See Figure 13. ^ Disconnect brake booster vacuum line from throttle body adapter. ^ Remove brake booster vacuum line bracket from intake manifold. Position vacuum line assembly away from intake manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1922 ^ Disconnect Idle Air Control (IAC) motor electrical connector. See Figure 14. ^ Disconnect left side radio interference suppressor electrical connector. Refer to Figure 15. ^ Disconnect DPFE transducer electrical connector. Refer to Figure 15. ^ Disconnect EVR solenoid electrical connector. Refer to Figure 15. ^ Disconnect Throttle Position (TP) sensor electrical connector. Refer to Figure 15. ^ Disconnect Engine Coolant Temperature (ECT) sensor electrical connector. See Figure 15. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1923 ^ Disconnect camshaft position (CMP) sensor electrical connector. See Figure 16. ^ Disconnect ignition coil electrical connectors from left side of engine. Refer to Figure 17. ^ Disconnect fuel injector electrical connectors from left side of engine. See Figure 17. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1924 ^ Remove left side fuel charge harness from cam cover studs, then position harness away from cam cover. See Figure 18. ^ Remove left side ignition coils from vehicle. WARNING DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. WARNING FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. 27. Relieve fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on EFI/CFI fuel pressure gauge. ^ Remove fuel pressure gauge and reinstall schrader valve cap. 28. Disconnect fuel lines from fuel manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1925 29. Remove junction block splash shield. See Figure 19. 30. Disconnect positive leads from starter relay. Refer to Figure 20. 31. Unclip two (2) mega-fuses from bracket. Refer to Figure 20. 32. Disconnect two (2) 42-pin bulkhead electrical connectors. Refer to Figure 20. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1926 33. Remove both bulkhead electrical connector halves from bracket. See Figure 20. 34. Disconnect 16-pin electrical connector. Refer to Figure 21. 35. Disconnect single-pin electrical connector. Refer to Figure 21. 36. Remove junction block bracket. See Figure 21. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1927 37. Remove heater supply hose from vehicle. Refer to Figure 22. 38. Disconnect heater return hose from heater core fitting. Then position hose away from right cam cover. Refer to Figure 22. 39. Remove ground strap to bulkhead retaining bolt, then unwrap ground strap from fuel manifold. See Figure 22. 40. Remove PCV valve and line from vehicle. 41. On 4.6L engines, proceed as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1928 ^ Disconnect right side coil pack electrical connector. Refer to Figure 23. ^ Disconnect right side radio interference suppressor electrical connector. Refer to Figure 23. ^ Disconnect ignition wires from right side coil pack. See Figure 23. ^ Remove right side coil pack from vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1929 ^ Unclip right side fuel charge harness from cam cover studs. Refer to Figure 24. ^ Unclip ignition wire separators from right cam cover studs. See Figure 24. ^ Disconnect ignition wires from right side spark plugs. Route ignition wires to front of engine. ^ Disconnect right side fuel injector electrical connectors. ^ Disconnect Engine Coolant Temperature (ECT) sensor electrical connector. Refer to Figure 25. ^ Disconnect water temperature sender electrical connector. Refer to Figure 25. ^ Remove tie strap retaining alternator wiring harness to fuel manifold. See Figure 25. 42. On 5.4L engines, proceed as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1930 ^ Disconnect right side radio interference suppressor. See Figure 26. ^ Disconnect ignition coil electrical connectors from right side of engine. Refer to Figure 27. ^ Disconnect fuel injector electrical connectors from right side of engine. See Figure 27. ^ Remove right side fuel charge harness from cam cover studs, then position harness away from cam cover. ^ Remove right side ignition coils from vehicle. ^ Remove tie strap retaining alternator wiring harness to fuel manifold. 43. Disconnect upper radiator hose from thermostat housing. 44. Remove drive belt. 45. Remove alternator and mounting bracket as an assembly. The ignition wires and the alternator wiring harness will also be removed with the alternator assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1931 46. Disconnect cylinder head temperature (CHT) sensor electrical connector. Refer to Figure 28. 47. Disconnect tuning valve electrical connector. See Figure 28. 48. Remove the intake manifold retaining bolts. See Figure 29. 49. Remove intake manifold from vehicle. 50. Remove and discard intake manifold gaskets. NOTE: On 5.4L engine, cam cover bolts cannot be separated from cam cover. NOTE: Be careful not to damage cam cover gaskets, as they will be reused. Remove both camshaft covers. 51. Remove both camshaft covers. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1932 52. Disconnect heater return hose from coolant tube, then remove heater hose from vehicle. Refer to Figure 30. 53. Remove retainers securing routing bracket to rear of right-hand cylinder head, then remove routing bracket and ground strap. Refer to Figure 30. 54. Remove coolant tube retainers securing coolant tube to rear of right hand cylinder head, then remove coolant tube. See Figure 30. 55. Remove jack handle from radiator air deflector. 56. Remove air deflector on top of radiator. 57. Disconnect coolant recovery hose from radiator. 58. Using Fan Clutch Holding Tool T84T-6312-C and Fan Clutch Wrench T93T-6312-B, remove cooling fan and clutch assembly. 59. Remove cooling fan shroud. 60. On automatic transmission models, disconnect transmission lines from radiator. 61. Disconnect lower radiator hose from radiator. 62. Remove radiator support brackets, then the radiator. 63. Remove water pump pulley, then the water pump. 64. On 4.6L and 5.4L Windsor engines, proceed as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1933 ^ Remove two (2) upper power steering pump retaining bolts. Refer to Figure 31. ^ Raise vehicle. ^ Remove one (1) lower power steering pump retaining bolt, then position power steering pump away from front engine cover. See Figure 31. 65. On Romeo engines, proceed as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1934 ^ Remove two (2) upper power steering pump retaining bolts. See Figure 32. ^ Raise vehicle. NOTE: One of the following bolts cannot be completely removed from the power steering pump due to clearance with the power steering line. ^ Remove two (2) lower power steering pump retaining bolts, then position power steering pump away from front engine cover. See Figure 33. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1935 66. Remove four (4) front oil pan bolts. See Figure 34. 67. Lower vehicle. 68. Using Crankshaft Damper Remover T58P-6316-D, remove crankshaft pulley. 69. Using Front Cover Seal Remover T74P-6700-A, remove engine front cover oil seal. 70. Remove idler pulley from right side of engine front cover. This pulley blocks a front cover bolt. 71. Remove engine front cover retainers. See Figure 35. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1936 72. Remove engine front cover from engine. See Figure 36. 73. Remove crankshaft sensor ring. 74. Using Crankshaft Holding Tool T93P-6303-A, rotate crankshaft until crankshaft keyway points to the 12 o'clock position. See Figure 37. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1937 75. Install Camshaft Holding Tool T96T-6256-B, on each camshaft. See Figure 38 for holding tool placement. 76. Remove both timing chain tensioners. See Figure 39. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1938 77. Remove both timing chain tensioner guides. See Figure 40. 78. Lift right-hand timing chain off camshaft sprocket, then slide timing chain and crankshaft sprocket off crankshaft. Refer to Figure 41. 79. Lift left-hand timing chain off camshaft sprocket, then slide timing chain and crankshaft sprocket off crankshaft. See Figure 41. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1939 80. Remove both timing chain guides. See Figures 42 and 43. NOTE: Removal of this wheel opening molding screw is necessary to access all screws for the fender splash shield. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1940 81. On 4X4 models, remove one (1) screw shown in Figure 44, from both wheel opening moldings. 82. Remove both front fender splash shields. See Figure 45. 83. Raise vehicle. 84. Disconnect exhaust Y-pipe from exhaust manifolds. 85. Slightly lower vehicle. Exhaust manifold retainers will be accessed through the wheel well opening. 86. Remove left side exhaust manifold and gasket. Retain gasket for reuse. Replace gasket if damaged. 87. Loosen engine oil indicator tube; then turn tube away from cylinder head. Removal of indicator tube is not necessary. 88. Remove right side exhaust manifold and gasket. Retain gasket for reuse. Replace gasket if damaged. 89. Remove retainer securing transmission indicator tube to right cylinder head if equipped. NOTE: Cylinder head bolts that are under the camshaft holding tools cannot be completely removed from the head due to clearance with the holding tool. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1941 Completely loosen these bolts. 90. Remove both cylinder heads. See Figure 46. Discard all cylinder head bolts. 91. Remove and discard both cylinder head gaskets. 92. On Romeo engines, proceed as follows: ^ Remove spark plugs from right cylinder head. ^ Remove camshaft sprocket from right side camshaft. ^ Remove Camshaft Holding Tool from right side camshaft. ^ Install camshaft sprocket on new right side camshaft. Do not final tighten retaining bolt at this time. ^ Remove spark plugs from left cylinder head. ^ Remove camshaft sprocket from left side camshaft. ^ Remove Camshaft Holding Tool from left side camshaft. ^ Install camshaft sprocket on new left side camshaft. Do not final tighten retaining bolt at this time. ^ Remove power steering reservoir bracket and CHT sensor from left cylinder head. 93. On 4.6L and 5.4L Windsor engines, proceed as follows: ^ Remove Camshaft Holding Tools from both camshafts. ^ Remove power steering reservoir bracket and Cylinder Head Temperature sensor from left cylinder head. ^ Remove all eight (8) spark plugs from cylinder heads. 94. Clean the following gasket surfaces: ^ Cylinder block to cylinder head. ^ Engine front cover. ^ Water pump. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1942 ^ Intake manifold. ^ Both cam covers. Installation 1. On all cylinder heads, install one (1) pipe plug into the rear of each cylinder head in locations shown in Figure 47. 2. On 4.6L Romeo engines, install one (1) pipe plug into the front of each cylinder head in locations shown in Figure 48. 3. Install CHT sensor to left cylinder head. Tighten sensor to 24-28 Nm (17-20 lb-ft). 4. Install power steering bracket to left cylinder head. 5. Install all spark plugs (both sides). Tighten plugs to 9-20 Nm (81-178 lb-in). 6. Install right cylinder head gasket. 7. Install right cylinder head. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1943 8. Tighten right cylinder head bolts in sequence shown in Figure 49 in the following three (3) stages: ^ Stage 1: 37-43 Nm (27-32 lb-ft). ^ Stage 2: Rotate 85-95 degrees. ^ Stage 3: Rotate 85-95 degrees. 9. Lubricate all camshaft journals. 10. Install left cylinder head gasket. 11. Install left cylinder head. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1944 12. Tighten left cylinder head bolts in sequence shown in Figure 50 in the following three (3) stages: ^ Stage 1: 37-43 Nm (27-32 lb-ft). ^ Stage 2: Rotate 85-95 degrees. ^ Stage 3: Rotate 85-95 degrees. 13. Lubricate all camshaft journals. 14. Raise vehicle. 15. Install transmission indicator tube retainer to right cylinder head if equipped. Tighten retainer to 18-23 Nm (14-16 lb-ft). 16. Install right side exhaust manifold gasket. NOTE: Due to clearance, the exhaust system Y-pipe mounting flange cannot be positioned on the exhaust manifold outlet after the exhaust manifold is installed on the cylinder head. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1945 17. Install right side exhaust manifold and gasket. Align exhaust system Y-pipe mounting flange with the studs in the exhaust manifold outlet before completely installing the exhaust manifold on the cylinder block. Tighten right side exhaust manifold retainers in sequence shown in Figure 51 to 18-22 Nm (13-16 lb-ft). 18. Position engine oil indicator tube in installed position. 19. Install left side exhaust manifold and gasket. Tighten retainers in sequence shown in Figure 52 to 18-22 Nm (13-16 lb-ft). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1946 20. Remove oil pan drain plug. Completely drain any fluid (oil, coolant) from oil pan. Reinstall drain plug, tightening to 11-16 Nm (98-143 lb-in). 21. Replace oil filter. 22. Install exhaust system Y-pipe to exhaust manifolds. Tighten retainers to 34-46 Nm (25-34 lb-ft). 23. Lower vehicle. 24. Install both fender splash shields. Tighten retainers to 10-13 Nm (89-115 lb-in). 25. On 4X4 models, install one screw removed from both wheel opening moldings. 26. On Romeo engines, proceed as follows: ^ Using socket on camshaft sprocket bolt, rotate left camshaft until timing mark is in 12 o'clock position. Refer to Figure 53. ^ Using socket on camshaft sprocket bolt, rotate right camshaft until timing mark is in 11 o'clock position. Refer to Figure 53. 27. On 4.6L and 5.4L Windsor engines, proceed as follows: ^ Using Camshaft Positioning Tool T96T-6256-AR, rotate left camshaft until timing mark is in 12 o'clock position. Refer to Figure 53. ^ Using Camshaft Positioning Tool T96T-6256-AR, rotate right camshaft until timing mark is in 11 o'clock position. See Figure 53. ^ Install Camshaft Holding Tool T96T-6256-B on each camshaft. 28. On Romeo engines, tighten both camshaft sprocket bolts to 110-130 Nm (81-95 lb-ft). CAUTION Rotate the crankshaft counterclockwise only. Do not rotate past position shown or severe piston and/or valve damage can occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1947 29. Rotate crankshaft using Crankshaft Holding Tool T93P-6303-A. See Figure 54. Fully install holding tool. This will position crankshaft keyway to about 10:30 position. 30. Remove Crankshaft Holding Tool. 31. Compress timing chain tensioner plunger as follows: CAUTION Do not compress the ratchet assembly. This will damage the ratchet assembly. CAUTION Use protective vocers over jaws of vise to prevent damage to tensioner. ^ Compress tensioner plunger using edge of vise. See Figure 55. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1948 ^ Using small screwdriver or pick, push back and hold ratchet mechanism. See Figure 56. ^ While holding ratchet mechanism, push ratchet arm back into tensioner housing. See Figure 57. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1949 ^ Install paper clip into hole in tensioner housing. This will hold ratchet assembly and plunger in during installation. See Figure 58. ^ Remove tensioner from vise. ^ Repeat procedure for second tensioner. 32. If copper links are not visible, mark one (1) link on each end of the timing chain. One link will be an inside link. Use these marks as timing marks. See Figure 59. Repeal this step for other timing chain, if necessary. 33. Install right side timing chain guide. Tighten retainers to 8-12 Nm (71-106 lb-in). 34. Install left side timing chain guide. Tighten retainers to 8-12 Nm (71-106 lb-in). 35. Install timing chains and sprockets as follows: ^ Position left side crankshaft sprocket in left side timing chain. Make sure crankshaft sprocket hub is facing outward. Align mark on timing chain with corresponding dot on crankshaft sprocket. ^ Slide left side sprocket and chain on crankshaft. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1950 ^ Position left side timing chain over camshaft sprocket, aligning timing mark on chain with dot on camshaft sprocket. If necessary, loosen camshaft holding tool and adjust camshaft sprocket to obtain timing mark alignment. Tighten camshaft holding tool after timing marks are aligned. ^ Position right side crankshaft sprocket in right side timing chain. Make sure crankshaft sprocket hub is facing inward. Align mark on timing chain with corresponding dot on crankshaft sprocket. ^ Slide right side sprocket and chain on crankshaft. ^ Position right side timing chain over camshaft sprocket, aligning timing mark on chain with dot on camshaft sprocket. If necessary, loosen camshaft holding tool and adjust camshaft sprocket to obtain timing mark alignment. Tighten camshaft holding tool after timing marks are aligned. ^ Make sure marks on timing chain are lined up with corresponding dots on crankshaft and camshaft sprockets. See Figure 60. ^ Make sure right side crankshaft sprocket is in front of left side crankshaft sprocket with hubs facing each other. See Figure 61. 36. Install right and left timing chain tensioner guides. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1951 37. Install right and left timing chain tensioners. Tighten retainers to 20-30 Nm (15-20 lb-ft). 38. Remove paper clips from both timing chain tensioners. 39. Remove both camshaft holding tools. 40. Install crankshaft sensor ring. 41. Install engine front cover as follows: NOTE: The engine front cover must be installed within four (4) minutes after applying silicone. Apply Silicone Gasket and Sealant F6AZ-1 9562-AA or equivalent, along head to block surface and oil pan to block surface. See Figure 62. ^ Using new gasket, install engine front cover. Align cover with cylinder block dowel. ^ Loosely install engine front cover bolts and stud bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1952 ^ Tighten first five (5) engine front cover bolts in sequence shown in Figure 63, to 20-30 Nm (15-22 lb-ft). ^ Tighten remaining ten (10) engine front cover bolts in sequence shown in Figure 64. On Romeo engines, tighten bolts to 20-30 Nm (15-22 lb-ft). On 4.6L and 5.4L Windsor engines, tighten bolts to 40-55 Nm (29-40 lb-ft). 42. Install right side idler pulley. Tighten retainer to 20-30 Nm (15-22 lb-ft). 43. Using clean engine oil, lubricate engine front cover oil seal inner lip. 44. Using Crankshaft Seal Replacer/Aligner T88T-6701-A, install front cover oil seal. 45. Install crankshaft pulley as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1953 NOTE: The crankshaft pulley must be installed within four (4) minutes after applying silicone. Apply Silicone Gasket and Sealant F6AZ-1 9562-AA or equivalent, to woodruff key slot on crankshaft pulley. See Figure 65. ^ Using Crankshaft Damper Replacer T74P-6316-B, install crankshaft pulley. ^ Loosely install crankshaft pulley bolt. ^ Tighten crankshaft pulley bolt to 90 Nm (66 lb-ft). ^ Loosen crankshaft pulley bolt one (1) full turn. ^ Tighten crankshaft pulley bolt to 47-53 Nm (34-39 lb-ft). ^ Tighten crankshaft pulley bolt an additional 85-90 degrees (1/4 turn). 46. On Romeo engines, proceed as follows: ^ Position power steering pump in installed position. Tighten two (2) upper bolts to 20-30 Nm (15-22 lb-ft). ^ Raise vehicle. ^ Install two (2) power steering pump lower retaining bolts. Tighten bolt to 20-30 Nm (15-22 lb-ft). 47. On 4.6L and 5.4L Windsor engines, proceed as follows: ^ Position power steering pump in installed position. Tighten two (2) upper bolts to 20-30 Nm (15-22 lb-ft). ^ Raise vehicle. ^ Install power steering pump lower retaining bolt. Tighten bolt to 20-30 Nm (15-22 lb-ft). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1954 48. Loosely install four (4) front oil pan bolts. Tighten bolts in sequence shown in Figure 66, in the following two (2) stages: ^ Stage 1: 20 Nm (15 lb-ft). ^ Stage 2: Rotate an additional 60 degrees. 49. Lower vehicle. 50. Using coolant, lubricate new water pump O-ring seal. Install seal on water pump. 51. Install water pump. Tighten retainers in sequence shown in Figure 67, to 20-30 Nm (15-22 lb-ft). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1955 52. Install water pump pulley. Tighten retainers in sequence shown in Figure 68, to 20-30 Nm (15-22 lb-ft). 53. Install radiator. Make sure radiator is sitting on mounting insulators. 54. Install radiator supports. Tighten retainers to 25-35 Nm (18-26 lb-ft). 55. Connect lower radiator hose to radiator. 56. On automatic transmission models, connect transmission cooler lines to radiator. Tighten lines to 16-24 Nm (12-18 lb-ft). 57. Install cooling fan shroud. Tighten retainer 108-10 Nm (71-89 lb-in). 58. Using Fan Clutch Holding Tool T84T-6312-C and Fan Clutch Wrench T93T-6312-B, install cooling fan and clutch assembly. 59. Connect coolant recovery hose to radiator. 60. Install air deflector on top of radiator. 61. Install jack handle on radiator air deflector. 62. Using clean coolant, lubricate coolant tube O-ring seal. Install coolant tube. Tighten retainers on rear of right cylinder head to 40-55 Nm (29-40 lb-ft). NOTE: Make sure left side fuel charge harness is between routing bracket and cylinder head. 63. Install routing bracket and ground strap to rear of right cylinder head. Tighten retainers to 9-12 Nm (80-107 lb-in). 64. Install heater return hose to coolant tube. 65. Install cam cover gaskets on both cam covers. NOTE: The cam cover must be installed within four (4) minutes after applying silicone. 66. Apply Silicone Gasket and Sealant F6AZ-1 9562-AA or equivalent, to the two (2) places where the engine front cover meets the cylinder head. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1956 67. Install right side cam cover. Tighten retainers in sequences shown in Figures 69 and 70, to 8-12 Nm (71-107 lb-in). NOTE: The cam cover must be installed within four (4) minutes after applying silicone. 68. Apply Silicone Gasket and Sealant F6AZ-19562-AA or equivalent, to the two (2) places where the engine front cover meets the cylinder head. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1957 69. Install left side cam cover. Tighten retainers in sequences shown in Figures 71 and 72, to 8-12 Nm (71-107 lb-in). 70. Install new intake manifold gaskets. 71. Install intake manifold (including thermostat housing). Tighten bolts in sequence shown in Figure 73, in the following two (2) stages: ^ Stage 1: 2 Nm (18 lb-in). ^ Stage 2: 20-30 Nm (15-22 lb-ft). 72. Loosely position left side fuel charge harness on cam cover. 73. Connect tuning valve electrical connector. 74. Connect CHT sensor electrical connector. 75. Install alternator assembly. Tighten front alternator bolts to 21-28 Nm (15-21 lb-ft). Tighten alternator bracket bolts to 9-12 Nm (80-106 lb-in). 76. Install drive belt. 77. Using tie strap, retain alternator wiring harness to fuel manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1958 78. On 4.6L engines, proceed as follows: ^ Loosely position right side fuel charge harness on cam cover. ^ Connect water temperature sensor electrical connector. ^ Connect ECT sensor electrical connector. ^ Connect right side ignition wires to spark plugs. ^ Clip ignition wire separators to right cam cover. ^ Connect right side fuel injector electrical connectors. ^ Clip right side fuel charge harness to cam cover. ^ Install right side ignition coil. Tighten retainers to 20-30 Nm (15-22 lb-ft). ^ Connect ignition wires to right side coil. ^ Connect right side radio interference suppressor electrical connector. ^ Connect right side coil pack electrical connector. 79. On 5.4L engines, proceed as follows: ^ Install right side ignition coils. Tighten retainers to 5-7 Nm (44-62 lb-in). ^ Position right side fuel charge harness on cam cover studs. ^ Connect right side fuel injector electrical connectors. ^ Connect right side ignition coil electrical connectors. ^ Connect right side radio interference suppressor. 80. Install PCV valve and line assembly. 81. Connect ground strap to bulkhead. 82. Connect heater return hose to heater core. 83. Install heater supply hose. 84. Install junction block bracket. Tighten retainers securely. 85. Connect single-pin electrical connector. 86. Connect 16-pin electrical connector. 87. Install both 42-pin bulkhead electrical connector halves to junction block bracket. 88. Connect both 42-pin bulkhead electrical connectors. Tighten retainers to 4-5 Nm (35-44 lb-in). 89. Clip two (2) mega-fuses to junction block bracket. 90. Connect positive leads to starter relay. 91. Install junction block bracket splash shield. 92. Connect fuel lines to fuel manifold. 93. On 4.6L engines, proceed as follows: ^ Connect left side ignition wires to spark plugs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1959 ^ Clip ignition wire separators to left cam cover. ^ Connect left side fuel injector electrical connectors. ^ Clip left side fuel charge harness to cam cover. ^ Install left side ignition coil. Tighten retainers to 20-30 Nm (15-22 lb-ft). ^ Connect ignition wires to left side coil. ^ Connect left side radio interference suppressor electrical connector. ^ Connect CMP electrical connector. ^ Connect left side coil pack electrical connector. ^ Connect DPFE transducer electrical connector. ^ Connect IAC motor electrical connector. ^ Connect TP sensor electrical connector. ^ Connect EVR solenoid electrical connector. ^ Connect crankcase vent tube to left cam cover. ^ Position power steering reservoir and bracket in installed position. Tighten upper retainers to 8-12 Nm (71-107 lb-in). Tighten lower retainers to 35-45 Nm (26-33 lb-ft). 94. On 5.4L engines, proceed as follows: ^ Install left side ignition coils. Tighten retainers to 5-7 Nm (44-62 lb-in). ^ Connect left side fuel injector electrical connectors. ^ Connect left side ignition coil electrical connectors. ^ Connect ECT sensor electrical connector. ^ Connect TP sensor electrical connector. ^ Connect EVR solenoid electrical connector. ^ Connect DPFE transducer electrical connector. ^ Connect left side radio interference suppressor electrical connector. ^ Connect IAC motor electrical connector. ^ Connect brake booster vacuum line to throttle body adapter, then install brake booster vacuum line bracket to intake manifold. ^ Connect VMV purge line to top of throttle body adapter. ^ Position vacuum harness on top of motor. ^ Connect vacuum tap to right side of throttle body adapter. ^ Connect EVR solenoid vacuum line. ^ Connect EGR valve vacuum line. ^ Connect fuel pressure regulator vacuum line. ^ Connect vapor management valve vacuum line. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1960 95. Connect EGR tube to EGR valve. Hand-tighten fitting at this time. 96. Connect DPFE transducer hoses to EGR tube. 97. On 4X4 models, connect A/C clutch electrical connector. 98. Raise vehicle. 99. Connect EGR tube to exhaust manifold. Tighten fitting to 35-45 Nm (26-33 lb-ft). 100. On 4X2 models, connect A/C clutch electrical connector. 101. Connect CKP sensor electrical connector. 102. Connect oil pressure switch electrical connector. 103. Lower vehicle. 104. Final tighten EGR tube to valve to 35-45 Nm (26-33 lb-ft). 105. On 4.6L engines, proceed as follows: ^ Loosely position vacuum harness over engine. ^ Connect EVR solenoid vacuum line. ^ Connect EGR valve vacuum line. ^ Connect fuel pressure regulator vacuum line. ^ Connect vapor management valve vacuum line. ^ Position brake booster vacuum line in installed position. Connect line to tap on throttle body adapter. Tighten line retainer at EGR valve to 8-12 Nm (71-106 lb-in). ^ Connect vacuum tap on right side of throttle body adapter. ^ Connect VMV vacuum line at rear of throttle body adapter. 106. On 5.4L engines, proceed as follows: ^ Connect crankcase vent tube to left cam cover. ^ Position power steering reservoir and bracket in installed position. Tighten upper retainers to 8-12 Nm (71-107 lb-in). Tighten lower retainers to 35-45 Nm (26-33 lb-ft). 107. Position accelerator/speed control cables on top of engine. Secure cables to clip on power steering reservoir. 108. Install accelerator cable bracket to intake manifold. Tighten retainer to 6-8 Nm (53-71 lb-in). 109. Connect accelerator cable, speed control cable and return spring to throttle body. 110. Connect upper radiator hose to thermostat housing. 111. Install rear half of air cleaner. 112. Install front half of air cleaner and clean air lube. 113. Connect IAT and MAF electrical connectors. 114. Install throttle body shield. 115. Connect battery negative cable. 116. Remove memory saver. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1961 117. Fill engine with new engine oil. 118. Fill cooling system as follows: ^ Add 50/50 coolant mixture to radiator coolant recovery reservoir. ^ Install radiator cap. ^ Move temperature blend selector to full warm position. ^ Run engine until it reaches operating temperature. ^ Add 50/50 coolant mixture to radiator coolant recovery reservoir until the coolant level is between the "COOLANT FILL LEVEL" marks. ^ Turn off engine and allow cooling system to cool. ^ Repeat bulleted steps until radiator coolant recovery reservoir level remains in between fill level marks when engine is cool. 119. On air suspension equipped models, turn air suspension switch to ON position. 120. Check engine for proper operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1962 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1963 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1964 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1965 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 1966 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant: > 01-23-6 > Nov > 01 > Engine Coolant - Propylene Glycol Recommendations Coolant: All Technical Service Bulletins Engine Coolant - Propylene Glycol Recommendations Article No. 01-23-6 11/26/01 ^ ENGINE COOLANT - PROPYLENE GLYCOL - FORD MOTOR COMPANY POSITION ON ENGINE COOLANTS MADE FROM PROPYLENE GLYCOL ^ ENGINE COOLANT - PROPYLENE GLYCOL-BASED - FORD MOTOR COMPANY POSITION ON PROPYLENE GLYCOL-BASED ENGINE COOLANTS FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2002 FOCUS 2002 THUNDERBIRD 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT 2000-2002 F-650, F-750 LINCOLN: 1989-1992 MARK VII 1989-2002 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1989-1994 TOPAZ 1989-1997 COUGAR 1989-2002 GRAND MARQUIS, SABLE 1991-1994 CAPRI 1991-1999 TRACER 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER MERKUR: 1989 SCORPIO, XR4TI This article is being republished in its entirety to update the model year coverage. ISSUE This TSB article describes Ford Motor Company's position on the use of propylene glycol-based engine coolants. ACTION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant: > 01-23-6 > Nov > 01 > Engine Coolant - Propylene Glycol Recommendations > Page 1972 Ford Motor Company does not recommend nor endorse the use of engine coolants made with propylene glycol in Ford vehicles. Ford Motor Company currently recommends the use of ethylene glycol-based engine coolants. Published information suggests that engine coolants made with propylene glycol may provide engine cooling performance equivalent to engine coolants made with ethylene glycol. However, different brands of engine coolant provide varying corrosion protection for the cooling system. Ford does not have performance data for the multitude of engine coolants available in the aftermarket and therefore cannot recommend the use of any coolant except those sold by Ford Customer Service Division. Consult the vehicle's Owner's Guide to determine the appropriate Ford Customer Service Division coolant for the vehicle. Furthermore, claims of toxicological and environmental advantages of propylene glycol over ethylene glycol may be misleading. When significant new information is developed, Ford will review this policy. Ford Motor Company specifications recommend that vehicles be maintained using certain ethylene glycol-based engine coolants. Those specifications do not refer to engine coolants made with propylene glycol. Although the Ford New Vehicle Limited Warranty is not automatically voided upon the use of a coolant made with propylene glycol, if such use results in damage to the vehicle or its components, the cost of repairing the damage would not be covered by the Ford New Vehicle Limited Warranty. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-16-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Capacity 19.2 qts .............................................................................................................................................................. ..................................................... Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1975 Coolant: Fluid Type Specifications COOLING SYSTEM FLUID, PREMIUM Ford Part No. U.S.A (Except Oregon) ............................................................................................................................................................ E2FZ-19549-AA or -B Canada ............................................................................................................ .............................................................................................. CXC-8-B Oregon .................................. ............................................................................................................................................................. F5FZ-19549-CC Ford Specification ................................................................................................................................ ................................................... ESE-M97B44-A COOLING SYSTEM FLUSH Ford Part No. ....................................................................................................................................... ................................................... F1AZ-19A503-A Ford Specification ................................................. ..................................................................................................................................... ESR-M14P7-A Coolant Mixture with Water ................................................................................................................. ...................................................................... 50% Warning: Do not mix coolant types. Check the owners manual or refer to your local dealer for the correct coolant type. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage Fluid - A/T: Technical Service Bulletins A/T - Mercon V ATF Usage TSB 06-14-4 07/24/06 MERCON ATF IS BEING REPLACED BY MERCON V ATF AS A SERVICE FLUID. FORD: 1980-1997 Crown Victoria 1981-1997 Mustang, Thunderbird 1981-2003 Escort 1986-1993 Festiva 1986-1997 Taurus 1989-1997 Probe 1994-1997 Aspire 1995-2000 Contour 1980-1996 Bronco 1981-2003 F-150 1981-2004 E-Series, F-Super Duty 1983-1996 Ranger 1986-1996 Aerostar 1991-1997 Explorer 1993-2004 F-53 Motorhome Chassis 1995-1998 Windstar 1997-2004 Expedition 2000-2005 Excursion 2001-2007 Escape 1987-2000 F-B-Series 2000-2007 F-650, F-750 LINCOLN: 1980-1997 Town Car 1981-1997 Continental 1993-1997 Mark VIII 1998-2004 Navigator 2002-2003 Blackwood MERCURY: 1980-1997 Grand Marquis 1981-1997 Cougar 1986-1997 Sable 1987-1999 Tracer 1995-2000 Mystique 1999-2002 Cougar 1993-2002 Villager 1997 Mountaineer 2005-2007 Mariner MERKUR: 1985-1989 XR4TI This article supersedes TSB 01-15-7 to update the vehicle application chart. ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid. ACTION Beginning immediately all automatic transmission / transaxle applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will only continue for however long it takes to deplete what remains in inventory. SERVICE PROCEDURE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage > Page 1980 Service automatic transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V For proper fluid application on current and past model vehicles equipped with automatic transmissions I transaxles refer to the fluid usage chart. (Figure 1) CAUTION AUTOMATIC TRANSMISSIONS / TRANSAXLES THAT REQUIRE MERCON® V SHOULD STILL ONLY USE MERCON(R) V OR DUAL USAGE FLUID LABELED MERCON(R) / MERCON(R) V. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage > Page 1981 CAUTION MERCON(R) SP, MOTORCRAFT PREMIUM AUTOMATIC TRANSMISSION FLUID AND MOTORCRAFT M5 ATFS ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR TRANSMISSION DAMAGE. CAUTION THE FUNCTIONAL CHARACTERISTICS OF FLUIDS FOR CVT TRANSMISSIONS ARE VERY DIFFERENT THAN THOSE OF OTHER AUTOMATIC TRANSMISSION FLUIDS (ATFS). USE OF A FLUID OTHER THAN MOTORCRAFT CONTINUOUSLY VARIABLE CHAIN TYPE TRANSMISSION FLUID OR ONE LABELED AS MEETING MERCON(R) C WILL CAUSE FUNCTIONALITY CONCERNS AND INTERNAL TRANSMISSION DAMAGE. CAUTION DO NOT USE AUTOMATIC TRANSMISSION FLUID SUPPLEMENTS, ADDITIVES, TREATMENTS OR CLEANING AGENTS. Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications With E4OD Transmission A/T Fluid Capacity ............................................................................................................................... ......................................................... 13.2L (13.9 Qt) A/T Fluid Refill ..................................................................................................................................... ............................................................ 4.7L (5.0 Qt) NOTE: With engine at operating temperature, shift through all gears. Check fluid in PARK add fluid as needed. With 4R70W Transmission A/T Fluid .............................................................................................................................................. ............................................................. 4.7L (5.0 Qt) Initial refill. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1984 Fluid - A/T: Fluid Type Specifications NOTE: MERCON Automatic Transmission Fluid is being replaced by MERCON V as a service fluid. Automatic (4R70W) ............................................................................................................................. ..................................................... MERCON V ATF Automatic (4R100) ............................................................................................................................................................. MERCON or MERCON V ATF Automatic (E40D) ............................................................................................................................................................. MERCON or MERCON V ATF NOTE: Automatic transmissions requiring MERCON V should only be serviced with MERCON V, or fluid from a container that is specified as a dual usage fluid: MERCON/MERCON V. NOTE: Automatic transmissions requiring MERCON can not be serviced with MERCON, MERCON V, or dual usage fluids labeled MERCON/MERCON V. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1985 Fluid - A/T: Diagrams PARK Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1986 PARK Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1987 PARK Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1988 PARK Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1989 2 ND GEAR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1990 2 ND GEAR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1991 TCC RELEASE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1992 TCC RELEASE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1993 LINE/SRV PRESSURE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1994 PARK NON-PTO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1995 PARK NON-PTO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1996 1ST GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1997 2ND GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1998 3RD GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1999 4TH GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 2000 MANUAL 3RD GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 2001 MANUAL 2ND GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 2002 MANUAL 1ST GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > Condition Fluid - A/T: Testing and Inspection Condition 1. Perform the fluid level check. 2. Observe the color and odor of the fluid. It should be dark reddish, not brown or black. Odor can sometimes indicate that there is an overheating condition clutch disc failure or band failure. 3. Use an absorbent white facial tissue to wipe the fluid level indicator. Examine the stain for evidence of solids (specks of any kind) and for signs of antifreeze (gum or varnish on the fluid level indicator). If specks are present in the fluid or there is evidence of antifreeze, the transmission fluid pan must be removed for further inspection. If fluid contamination or transmission failure is confirmed by further evidence of coolant or excessive solids in the transmission fluid pan, the transmission must be disassembled and completely cleaned and serviced. This includes cleaning the torque converter and transmission cooling system. Do not perform any further checks before cleaning and servicing the transmission. During disassembly and assembly, all overhaul checks and adjustments of clearances and end play must be made. After the transmission has been serviced, all diagnostic tests and adjustments listed in the Diagnosis by Symptom chart must be completed to ensure the concern has been corrected. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > Condition > Page 2005 Fluid - A/T: Testing and Inspection Level Check CAUTION: - The vehicle should not be driven if the fluid level is below the COLD marked area on the fluid level indicator and outside temperature is above 10° C (50° F). - If vehicle has been operated for an extended period at high speed, in city traffic, in hot weather, or vehicle is being used to pull a trailer, the fluid has to cool approximately 30 minutes after engine had been turned off to obtain an accurate reading. Under normal circumstances, check the fluid level of the transmission during normal maintenance, and change it at 48,000 km (30,000 miles) since the vehicle does not use up transmission fluid. However, if the transmission is not working properly, the transmission may slip or shift slowly or there may be some sign of fluid leakage. The fluid level should he checked It is preferable to check the transmission fluid level at normal operating temperature after approximately 32 km (20 miles) of driving. If necessary, check the fluid level without driving the vehicle, if the outside temperature is above 10° C (50° F). When checking fluid at normal operating temperature, the fluid level should be within the HOT marked area on the fluid level indicator. When the vehicle has not been driven and outside temperature is above 10° C (50° F), the fluid level should be within the COLD marked area on the fluid level indicator. Check Fluid Level as Follows: NOTE:The fluid level on the fluid level indicator will be different at operating temperature and ambient temperature. For the correct fluid level reading on the fluid level indicator, follow the appropriate instructions. 1. With the transmission in Park (P), the engine at curb idle rpm, the foot brakes applied and the vehicle on a level surface, move the transmission range selector lever through each range. Allow time in each range to engage the transmission. Return to Park (P), apply the parking brake and block the wheels. Do not turn off the engine during the fluid level check. 2. Clean all dirt from the transmission fluid level indicator cap before removing the fluid level indicator from the fluid fill tube. 3. Pull the fluid level indicator out of the fluid fill tube, wipe it clean, and push it all the way back into the tube. Make sure it is fully seated. 4. Pull the fluid level indicator out of the fluid fill tube again and check the fluid level. If necessary, add enough fluid through the transmission fluid fill tube to raise the level to the correct position. Do not overfill the transmission. This will result in foaming, loss of fluid through the vent and possible transmission malfunction. If overfill occurs, excess fluid must be removed. 5. Install the fluid level indicator, making sure it is fully seated in the fluid fill tube. If the transmission fluid level is checked when the fluid is at ambient temperature, the fluid level indicator could indicate that fluid should be added if the fluid level indicator is misread. If fluid is added at this time, an overfill condition could result when the fluid reaches operating temperatures of 66° C-77° C (150° F-170° F) (fluid level indicator hot to touch). Underfill can result in transmission loss of engagement or slipping. This condition is most evident in cold weather or when the vehicle is parked or being driven on a hill. If the transmission fluid level is correctly established at 10-35° C (50-95° F), it will appear in the HOT marked area on the fluid level indicator when the transmission reaches an operating temperature of 66-77° C (150-170° F). Do not overfill or underfill. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > E4OD Fluid - A/T: Service and Repair E4OD NOTE: MERCON Automatic Transmission Fluid is being replaced by MERCON V as a service fluid. A fluid level that is too high may cause the fluid to become aerated due to the churning action of the rotating parts of the transmission. Aerated fluid will cause erratic control pressure, and the aerated fluid may be forced from the vent. A fluid level that is too low will affect transmission operation. Low fluid level may indicate fluid leaks that may cause transmission damage. CAUTION: Use of any fluid other than specified could result in transmission malfunction or failure. Use only Motorcraft MERCON or MERCON V Automatic Transmission Fluid or equivalent in all Ford automatic transmissions. Before adding any fluid, make sure the correct type will be used. Add fluid in 0.24 L (0.5 pint) increments through the fluid filler tube to bring the level to the correct area on the fluid level indicator. If an overfill occurs, remove excess fluid. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > E4OD > Page 2008 Fluid - A/T: Service and Repair 4R70W Adding Fluid NOTE: MERCON Automatic Transmission Fluid is being replaced by MERCON V as a service fluid. A fluid level that is too high may cause the fluid to become aerated due to the churning action of the rotating parts of the transmission. Aerated fluid will cause erratic control pressure, and the aerated fluid may be forced from the vent. A fluid level that is too low will affect transmission operation. Low fluid level may indicate fluid leaks that may cause transmission damage. CAUTION: Use of any fluid other than specified could result in transmission malfunction or failure. Use only Motorcraft MERCON or MERCON V Automatic Transmission Fluid or equivalent meeting FORD specification. Before adding any fluid, make sure the correct type will be used. Add fluid in 0.24 L (0.5 pint) increments through the fluid filler tube to bring the level to the correct area on the fluid level indicator. If an overfill occurs, remove excess fluid. Partial Drain and Refill NOTE: MERCON Automatic Transmission Fluid is being replaced by MERCON V as a service fluid. Normal maintenance requires periodic automatic transmission fluid changes. If a major service, such as a clutch, band, bearing, etc., is required, the automatic transmission fluid will also have to be removed for service. At this time, the torque converter, transmission cooler, cooler inlet tube and cooler tube must be thoroughly flushed to remove any dirt. When used under continuous or severe conditions, the transmission and torque converter should be drained and refilled with fluid as specified. Normal Maintenance Change fluid at 48,279 km (30,000 miles). Severe Duty/Major Overhaul Change fluid at 33,795 km (21,000 miles). CAUTION: Use of a fluid other than specified could result in transmission malfunction and/or failure. Refer to the vehicle certification label affixed to the LH front door lock face panel or door pillar for the transmission code. Procedures for partial drain and refill are as follows: 1. Raise vehicle on a hoist and position suitable safety stands under vehicle. WARNING: The electrical power to the air suspension system must be shut OFF prior to hoisting, jacking or towing an air suspension vehiclE. This can be accomplished by turning OFF the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. 2. Place drain pan under transmission. 3. Loosen transmission pan retaining bolts and allow fluid to drain from transmission. 4. When fluid has drained to level of pan flange, remove the transmission pan retaining bolts working from the right-hand side of the transmission. Carefully lower the transmission pan and drain remaining fluid. 5. Remove the pan to case gasket and thoroughly clean the transmission pan and pan magnet. 6. Drain the torque converter by removing the torque converter drain plug. 7. Thoroughly flush torque converter, auxiliary fluid cooler and lines. 8. After torque converter has been drained, install new torque converter drain plug. 9. Replace transmission fluid filter and seal as required. CAUTION: If replacing the filter and the seal remains in main control bore, carefully use a small screwdriver to remove it. Take care not to damage main control bore. NOTE: If servicing for contamination-related failure, use a new filter and seal. Filter may be reused if no excessive contamination is present. 10. Clean and inspect transmission pan to case gasket. If OK, reuse. Install pan to case gasket on transmission pan. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > E4OD > Page 2009 11. Install pan magnet in transmission pan. Install transmission pan to transmission. Tighten fourteen retaining bolts to proper torque. 12. Remove safety stands and lower vehicle. NOTE: If equipped with air suspension, reactivate the system by turning ON the air suspension switch. 13. When filling a dry transmission and converter, start with a minimum of 4.7 liters (5 quarts). 14. Fill transmission to proper level with Motorcraft MERCON or MERCON V Automatic Transmission Fluid or equivalent meeting FORD specification. Total Drain and Refill NOTE: MERCON Automatic Transmission Fluid is being replaced by MERCON V as a service fluid. REMOVAL 1. Raise and support the vehicle. WARNING: The electrical power to the air suspension system must be shut OFF prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning OFF the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. 2. Place a drain pan under the transmission fluid pan. 3. Drain the transmission fluid. - Loosen the transmission fluid pan bolts and allow the fluid to drain. After the fluid is drained remove the bolts. 4. Remove the (A) transmission fluid pan and the (B) transmission pan gasket. - Replace transmission pan gasket as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > E4OD > Page 2010 5. Pull down evenly and remove the transmission fluid filter, seal and filter kit. 6. Remove the converter housing access plug. 7. Remove the torque converter drain plug and drain the torque converter. - Rotate the crankshaft to access the drain plug. 8. Clean and inspect the (A) transmission fluid pan, the (B)pan gasket and the (C) magnet. 9. Flush the torque converter, cooler, and cooler lines. INSTALLATION 1. Install the new torque converter drain plug. NOTE: A new torque converter drain plug must be installed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > E4OD > Page 2011 2. Install the converter housing access plug. CAUTION: If replacing the filter, and the seal remains in the main control bore, carefully use a small screwdriver to remove the seal. Use care not to damage the main control bore. NOTE: If the transmission is being repaired for a contamination-related failure, use a new filter and seal. The filter may be reused if no excessive contamination is present. 3. Replace the fluid filter and seal as required. 4. Position the pan magnet into the transmission fluid pan. 5. Install the transmission fluid pan and gasket. (1) Position the transmission pan gasket. (2) Position the transmission fluid pan. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > E4OD > Page 2012 NOTE: The transmission pan gasket is reusable. Clean and inspect for damage; if not damaged, reuse the gasket. 6. Install the transmission fluid pan bolts. 7. Remove the supports and lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning ON the air suspension switch. 8. Fill the transmission to the proper fluid level. - Use Motorcraft MERCON or MERCON V Automatic Transmission Fluid or equivalent meeting FORD specification. NOTE: When filling a dry transmission and converter start with a minimum of 4.7 liters (5 quarts). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications With Dana 50 Axle Differential Fluid Capacity Capacity (Refill) ................................................................................................................................... .................................................................... 3.8 Pints With Dana 60 Axle Differential Fluid Capacity Capacity (Refill) ................................................................................................................................... .................................................................... 6.0 Pints Rear Differential Fluid Capacity With 8.8 & 9.75 Inch ring Gear ............................................................................................................ ................................................................... 5.5 Pints With 10.25 Inch ring Gear .................................................................................................................... .................................................................... 7.5 Pints Fill no higher than 1/4 to 9/16 inch below fill plug. 8.8 inch and 10.25 inch ring gear differentials have a removable cover. 9.25 inch does not. Limited slip type differentials include 4 oz of friction modifier C8AZ-19B956-A in capacity. To determine standard or limited slip type, check axle code on label on door lock pillar. Standard axles consist of two numbers. Limited slip codes consist of one letter and one number. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 2017 Fluid - Differential: Fluid Type Specifications Front Front Differential .................................................................................................................................. .......................................................... 75W-90 GL-5 Note: Part no. XY-75W90-QL meeting Ford Specification WSP-M2C201-A Rear Standard .............................................................................................................................................. .......................................... Synthetic 75W-140 GL-5 Limited Slip .......................................................................................................................................... ...................................... Synthetic 75W-140 GL-5+ Note: Part no. XY-75W140-QL Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications Capacity (Refill) ................................................................................................................................... ................................................................... 8.2 Pints Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 2022 Fluid - Transfer Case: Fluid Type Specifications TYPE .............................................................................................................................................................. MERCON(R) Automatic Transmission Fluid Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications Technical Service Bulletin # 02-1-9 Date: 020121 Engine Oil - Oil Recommendations/Applications Article No. 02-1-9 01/21/02 ENGINE - ENGINE OIL - RECOMMENDED APPLICATIONS FOR SAE 5W-20 AND SAE 5W-30 MOTOR OILS - GASOLINE AND FLEXIBLE FUEL VEHICLES ONLY FORD: 1992-2002 CROWN VICTORIA 1993-1994 TEMPO 1993-1997 THUNDERBIRD 1993-2002 ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 1998-2002 ESCORT ZX2 2000-2002 FOCUS 1993-1996 BRONCO 1993-1997 AEROSTAR 1993-2002 E SERIES, F-150, RANGER 1995-2002 WINDSTAR 1997-1999 F-250 LD 1997-2001 EXPLORER 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2002 EXCURSION 2001-2002 ESCAPE LINCOLN: 1991-2002 TOWN CAR 1993-1998 MARK VIII 1993-2002 CONTINENTAL 2000-2002 LS 1998-2002 NAVIGATOR MERCURY: 1992-2002 GRAND MARQUIS 1993-1994 TOPAZ 1993-1997 COUGAR 1993-1999 TRACER 1993-2002 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1997-2001 MOUNTAINEER This article is being republished in its entirety to update the vehicle models, engines and years affected. NOTE PLEASE REFER TO THE VEHICLE APPLICATION LIST LATER IN THIS TSB FOR A COMPLETE LIST OF VEHICLES AFFECTED BY THIS TSB. ISSUE Ford Motor Company now recommends SAE 5W-20 viscosity grade for servicing most gasoline and flexible fueled vehicles. ACTION All 2001 and 2002 vehicles where SAE 5W-20 is specified should be serviced at the recommended oil change intervals using SAE 5W-20. This oil is an improved formulation to improve fuel economy. Testing has validated this viscosity grade can be used in many previous model year vehicles. It is recommended ALL vehicles on the following Vehicle Application Listing be service with SAE 5W-20. All 2001-2002 vehicles other than those listed in the "Exception 2001 Vehicles" or "Exception 2002 Vehicles" chart are being filled with SAE 5W-20 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2027 motor oil at the factory and should also be serviced with SAE 5W-20 oil. Exception 2001 Vehicles Exception 2002 Vehicles NOTE IF VEHICLE IS NOT LISTED IN THIS APPLICATION, SAE 5W-30 OIL IS RECOMMENDED. REFER TO TSB 99-8-16. Parts Block OTHER APPLICABLE ARTICLES: 99-8-16 SUPERSEDES: 01-4-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 497000, 499000 Veh. App. Listing Approved For SAE 5W-20 Motor Oil ^ 1993-1996 1.9L Escort/Tracer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2028 ^ 1995-2000 2.0L Zetec Contour/Mystique ^ 1999-2002 2.0L Cougar ^ 1997-2002 2.0L Escort/Tracer ^ 1998-2002 2.0L Escort ZX2 ^ 2000-2002 2.0L Focus ^ 2001-2002 2.0L Escape ^ 1993-1997 2.3L Ranger ^ 1993-1994 2.3L Mustang ^ 1993-1994 2.3L Tempo/Topaz ^ 1998-2001 2.5L Ranger ^ 1995-2000 2.5L Contour/Mystique ^ 1999-2002 2.5L Cougar ^ 2001-2002 3.0L 4V Escape ^ 1996-2001 3.0L 4V Taurus/Sable ^ 1993-2002 3.0L (Vulcan) Aerostar/Ranger, ^ Taurus/Sable (Flexible Fuel and Gas) ^ 1995-2000 3.0L (Vulcan) Windstar ^ 1993-1994 3.0L (Vulcan) Tempo/Topaz ^ 2000-2002 3.0L 4V Lincoln LS ^ 1995-2002 3.8L Windstar ^ 1993-1997 3.8L Taurus/Sable, ^ Thunderbird/Cougar, Continental ^ 1994-2002 3.8L Mustang ^ 2002-2002 3.9L 4V Lincoln LS ^ 1997-2002 4.2L (SPI) F-150 (under 8500 GVW only), E-Series ^ 1996-2002 4.6L 2V Mustang ^ 1992-2002 4.6L Crown Victoria/Grand Marquis ^ 1991-2002 4.6L Town Car ^ 1994-1997 4.6L 2V Thunderbird/Cougar ^ 1996-2002 4.6L 4V Mustang Cobra ^ 1995-2002 4.6L 4V Continental ^ 1993-1998 4.6L 4V Mark VIII Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2029 ^ 1997-2002 4.6L 2V Triton F-150/250 (under 8500 GVW only), E-Series, Expedition ^ 1993-1999 4.9L E-Series, F-Series ^ 1993-1995 5.0L Mustang/Mustang Cobra ^ 1993-1993 5.0L Thunderbird/Cougar ^ 1997-2001 5.0L Explorer/Mountaineer ^ 1993-1996 5.0L E-Series, F-Series, Bronco ^ 2000-2002 5.4L Excursion ^ 1998-2002 5.4L 2V/4V Navigator ^ 1997-2002 5.4L 2V F-1501250 (under 8500 GVW only), Expedition, E-Series, E-350 Chassis/RV/Cutaway ^ 1993-1997 5.8L F-Series, Bronco ^ 1993-1996 5.8L E-Series ^ 2000-2002 6.8L Excursion ^ 1997-2002 6.8L E-Series, E-350 Chassis/RV/Cutaway ^ 1999-2002 6.8L Super Duty F-Series 250 HD/350/450/550 Motorhome ^ 1993-1998 7.5L All Vehicles NOTE FOR 1993 THROUGH 1998 MODEL YEAR FFV USE XO-10W30-FFV. NOTE THE "EXCEPTION 2001-2002 VEHICLES" SHOULD BE SERVICED WITH SAE 5W-30 MOTOR OIL Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2030 Engine Oil: Technical Service Bulletins Motor Oil - Viscosity Grade Recommendation Article No. 99-8-16 05/03/99 MOTOR OIL - SAE VISCOSITY GRADE RECOMMENDATION - SERVICE TIP FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-1999 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-1999 CONTOUR LINCOLN-MERCURY: 1989-1992 MARK VII 1989-1994 TOPAZ 1989-1997 COUGAR 1989-1999 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1991-1994 CAPRI 1994-1998 MARK VIII 1995-1999 MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-1999 ECONOLINE, F-150, F-250 LD, RANGER 1991-1999 EXPLORER 1993-1999 VILLAGER 1995-1999 WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE Ford Motor Company now recommends SAE 5W-30 viscosity grade for servicing any Ford gasoline-powered vehicle regardless of model year. ACTION When servicing any Ford gasoline-powered vehicle, use SAE 5W-30 viscosity grade motor oil. Refer to the following text for further details. Both SAE 10W-30 and SAE 5W-30 viscosity grade motor oils have been recommended in the past depending on vehicle model and model year. Tests have proven SAE 5W-30 viscosity grade motor oil provides the optimum protection and benefits for Ford gasoline engines. At both high and low ambient temperature conditions, SAE 5W-30 provides the best overall protection. It allows faster starts under cold ambient temperatures. SAE 5W-30 also provides approximately 1/2% increase in fuel economy over SAE 10W-30. SAE 5W-30 viscosity grade motor oils certified for gasoline engines by the American Petroleum Institute (API) should be used for all service procedures requiring replacement of the motor oil. PART NUMBER PART NAME XO-5W30-QSP 5W-30 Motorcraft Super Premium Motor Oil OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 499000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2031 Engine Oil: Technical Service Bulletins Engine - Oil Level Checking Incorrect in Owner's Guide Article No. 97-6-26 03/17/97 ^ ENGINE - CHECKING ENGINE OIL LEVEL IN OWNER'S GUIDE INCORRECT ^ OIL - CHECKING ENGINE OIL LEVEL IN OWNER'S GUIDE INCORRECT LIGHT TRUCK: 1997 EXPEDITION ISSUE: The oil level indicator illustration shown in the Service Section on Page 161 of the 1997 Expedition Owner's Guide is incorrect. ACTION: Inform customers who own the subject vehicle that the illustration is incorrect and show them the correct way to check the oil level. Refer to the following text for more details. The current Owner's Guide shows an illustration of the oil level indicator as being marked "ADD-FULL," which is incorrect. The illustration should read "MIN-MAX." The oil level should read between the "MIN-MAX" level on the indicator. If the level falls below "MIN," add oil as necessary to return the oil level to between the "MIN-MAX" level. Do not exceed the "MAX" mark or engine damage may occur. The following Steps will be printed in all subsequent Owner's Guides using "MIN-MAX" oil level indicators: 1. Make sure the vehicle is on level ground. 2. Turn off the engine and wait a few minutes for the oil to drain back into the oil pan. 3. Set the parking brake and make sure the gearshift is securely latched in "P" (automatic) or 1st gear (manual). 4. Open the hood. Protect yourself from engine heat. 5. Locate and carefully remove the engine oil level indicator (dipstick). 6. Wipe the indicator clean. 7. Insert the indicator fully and remove it again. a. If the oil level is between the "MIN-MAX" marks, the oil level is acceptable. DO NOT ADD OIL. b. If the oil level is below the "MIN" mark, add enough oil to raise the level to within the "MIN-MAX" marks. CAUTION: OIL LEVELS ABOVE THE "MAX" MARK MAY CAUSE ENGINE DAMAGE. SOME OIL MUST THEN BE REMOVED BY A SERVICE TECHNICIAN. 8. Put the indicator back in and make sure it is fully seated. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil Capacity ............................................................................................................................................... ............................................................. 5.7L (6.0 Qt) NOTE: Listed capacities are approximate. Check fluid level after filling. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2034 Engine Oil: Fluid Type Specifications Engine Oil Type Type ..................................................................................................................................................... .......................................................................... GF-1 Viscosity .............................................................................................................................................. ...................................................................... 5W-30 NOTE: Must meet Ford Specification M2C-153-F Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Mercon V(R) Fluid Usage TSB 07-1-7 01/22/07 MERCON(R) ATF REPLACED BY MERCON(R) V AS A SERVICE FLUID FOR SOME POWER STEERING SYSTEMS FORD: 1996-1997 Thunderbird 1996-2007 Crown Victoria, Mustang, Taurus 1998-2003 Escort 2000-2007 Focus 2002-2005 Thunderbird 2005-2006 Ford GT 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1996-1997 Aerostar 1996-2007 E-Series, Explorer, Ranger 1997-2004 F-53 Motorhome Chassis 1997-2007 Expedition, F-150, F-Super Duty 1998-2003 Windstar 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2007 Escape 2004-2007 Freestar 2005-2007 Escape Hybrid 1996-1997 Cargo 1996-1998 L-Series 1996-1999 F- B-Series 2000-2007 F-650, F-750 2006-2007 Low Cab Forward LINCOLN: 1996-1998 Mark VIII 1996-1999 Continental 1996-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 1996-1997 Cougar 1996-2005 Sable 1996-2007 Grand Marquis 1999-2002 Cougar 2003-2004 Marauder 2005-2007 Montego 2006-2007 Milan 1997-2007 Mountaineer 1998-2002 Villager 2004-2007 Monterey 2005-2007 Mariner Hybrid, Mariner ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid for power steering systems originally requiring MERCON(R). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage > Page 2039 ACTION Beginning immediately all power steering applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining inventory has been depleted. SERVICE PROCEDURE Service power steering Systems requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. CAUTION APPLICATIONS RECOMMENDING TYPE F AUTOMATIC TRANSMISSION AND POWER STEERING FLUID MUST CONTINUE TO USE THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 2040 Power Steering Fluid: Specifications Use Motorcraft MERCON(r) Multi-Purpose Transmission Fluid, XT-2-QDX or equivalent MERCON(r) approved fluid. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants Technical Service Bulletin # 99-19-6 Date: 990920 A/C - Identification of Non Approved Refrigerants Article No. 99-19-6 09/20/99 ^ AIR CONDITIONING - IDENTIFICATION OF NON-FORD APPROVED REFRIGERANTS ^ AIR CONDITIONING - PURGING AIR FROM SYSTEM FORD: 1985-1986 LTD 1985-1988 EXP 1985-1994 TEMPO 1985-1997 THUNDERBIRD 1985-2000 CROWN VICTORIA, ESCORT, MUSTANG 1986-2000 TAURUS 1988-1993 FESTIVA 1989-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2000 FOCUS 1985-1990 BRONCO II 1985-1996 BRONCO 1985-1997 F-250 HD, F-350 1985-2000 ECONOLINE, F-150, F-250 LD, RANGER 1986-1997 AEROSTAR 1988-1997 F SUPER DUTY 1991-2000 EXPLORER 1995-2000 WINDSTAR 1997-2000 EXPEDITION 1999-2000 SUPER DUTY F SERIES 1985-1991 CL-CLT-9000 SERIES 1985-1999 L SERIES 1985-2000 F & B SERIES 1986-1998 CARGO SERIES 1997-1998 AEROMAX, LOUISVILLE LINCOLN: 1985-1992 MARK VII 1985-2000 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000 LS 1998-2000 NAVIGATOR MERCURY: 1985-1986 MARQUIS 1985-1987 LYNX 1985-1994 TOPAZ 1985-1997 COUGAR 1985-2000 GRAND MARQUIS 1986-2000 SABLE 1987-1989 TRACER 1991-1994 CAPRI 1991-2000 TRACER 1995-2000 MYSTIQUE 1999-2000 COUGAR 1993-2000 VILLAGER 1997-2000 MOUNTAINEER MERKUR: 1985-1989 XR4TI 1988-1989 SCORPIO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 2045 This TSB article is being republished in its entirety to add model year vehicles ISSUE A number of non-approved/alternate refrigerants have entered the marketplace and are being advertised as "drop-in replacements" for R-12 and R-134a. The use of non-approved refrigerants such as R-22, hydrocarbons, and other refrigerant blends could cause safety, durability, and performance concerns if they are installed in Ford A/C systems. Identification of the type of refrigerant contained in vehicle A/C systems, before servicing, is necessary to prevent dealer service equipment and refrigerant supplies from being contaminated with non-approved refrigerants. ACTION Refrigerant identification must be performed prior to recovering the refrigerant into a recovery machine to prevent cross-contamination of the recovery machine and other A/C systems being serviced with that recovery machine. Refer to the following text. OTHER APPLICABLE ARTICLES: 94-14-3, 95-18-4 SUPERSEDES: 98-12-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1993-2000 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 991906A Test A/C System For 0.3 Hr. Contaminated Refrigerant DEALER CODING CONDITION BASIC PART NO. CODE R-12 49 OASIS CODES: 208000, 208999 A/C Refrigerant Analyzer Function Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 2046 Ford Motor Company has approved the Rotunda Deluxe A/C Refrigerant Analyzer (198-00003) for use on Ford and Lincoln-Mercury vehicles (Figure 1). The analyzer provides the technician with a quick and easy way to identify the type and percentage of refrigerant (R-134a, R-12, R-22, or flammable hydrocarbon). The analyzer can also provide the percentage of air in the A/C system and automatically purge air from the system. The A/C Refrigerant Analyzer is designed to identify vapor gas samples taken directly from automotive air conditioning systems or refrigerant storage cylinders. Refrigerant vapor passes through the multiple sensor Non-Dispersive Infra-Red (NDIR) sensing unit. The microprocessor calculates each refrigerant type and purity percentage which is displayed on the analyzer's Liquid Crystal Display (LCD). The analyzer identifies the purity percentage of R-134a, R-12, R-22, hydrocarbon; and air in the sample. If the purity percentage of the R-134a or R-12 is 98% or greater by weight, a green "PASS" Light Emitting Diode (LED) will light. If refrigerants R-134a or R-12 do not meet 98% purity levels, the red "FAIL" LED will light. Levels of R-22 and flammable hydrocarbons above 2% will light the red "FAIL" light. If a hydrocarbon is detected above 5%, both the "FAIL" light and "HYDROCARBON" light will illuminate and a horn will sound alerting the user of potential hazards. The percent of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or above. The analyzer eliminates the effect of air Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 2047 when determining the refrigerant sample content because air is not considered a contaminant although air can affect A/C system performance. Air will automatically be purged until a pure refrigerant with a less than 2% by weight air measurement is reached. Recovery of Contaminated Refrigerant If contaminated refrigerant is detected, DO NOT recover the refrigerant into your R-134a or R-12 recovery/recycling equipment. Take the following actions: 1. Repeat the test to verify contaminated refrigerant is present. 2. Advise the customer of the contaminated A/C system and any additional cost to repair the system. The customer may wish to return to the service facility which performed the last A/C service. 3. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. This equipment must only be used to recover contaminated refrigerant to prevent the spread to other vehicles. As an alternative, contact an A/C service facility in your area which has the proper equipment for refrigerant recovery. Repairing A Contaminated A/C System Once the contaminated refrigerant is removed from the system it will be necessary to repair the system. Ford recommends that you do the following to be sure a quality repair is made: 1. Determine the cause of the failure. 2. Determine which parts will need to be replaced. 3. Flush the heat exchangers to remove any oil that may be degraded due to the contaminated refrigerant. 4. Install a new suction/accumulator. 5. Properly oil match the system to verify that the correct amount of clean refrigerant oil is present in the system. 6. Evacuate the system for 45 minutes. 7. Recharge the system, verify proper operation, and leak test. Disposal of Contaminated Refrigerant Disposal of contaminated refrigerant is a new process to the automotive industry Listed below are companies that will assist with disposal of contaminated refrigerant. Ford Motor Company has not evaluated the processes of the listed refrigerant disposal companies and is not endorsing or promoting their companies Business transactions are between the dealership and disposal companies. Disposal costs will vary between $3.00 and $5.00 per pound, plus the cost of round trip cylinder shipping. ^ Omega Refrigerant Reclamation ^ 5263 North Fourth St. ^ Irwindale, CA 91706 ^ (310) 698-0991 FAX: (310) 696-7908 ^ Full Cycle Global ^ 2966 Wireton ^ Blue Island, IL 60406 ^ (708) 388-8551 FAX: (708) 399-6550 ^ U.S. Refrigerant Reclaim, Inc. ^ 12420 North Green River Road ^ Evansville, IN 47711 ^ (800) 207-5931 FAX: (812) 867-1463 ^ Full Cycle Global ^ 343 South Airline Highway Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 2048 ^ Gonzales, LA 70737 ^ (504) 644-5333 FAX: (504) 644-1609 ^ CFC Reclamation ^ 1321 Swift North ^ Kansas City, MO 64116 ^ (816) 471-2511 ^ Full Cycle Global ^ 550 James St. ^ Lakewood, NJ 08701 ^ (908) 370-3400 FAX: (908) 370-3088 ^ National Refrigerants, Inc. ^ 11401 Roosevelt Blvd. ^ Philadelphia, PA 19154 ^ (215) 698-6620 FAX: (215) 602-8205 ^ Gartech Refrigerant Reclamation ^ 2002 Platinum ^ Garland, TX 75042 ^ (214) 272-4070 FAX: (214) 272-6548 ^ Refrigerant Reclaim Services ^ 121 S. Norwood Dr. ^ Hurst, TX 76053-7807 ^ (817) 282-0022 FAX: (800) 831-6182 ^ Full Cycle Global ^ 2055 Silber, Suite 109 ^ Houston, TX 77055 ^ (713) 681-7370 FAX: (713) 681-9947 ^ Refrigerant Reclaim, Inc. ^ 122 Old Stage Coach Road ^ Dumfries, VA 22026 ^ (800) 238-5902 FAX: (703) 441-0393 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 2049 Technical Service Bulletin # 98-12-5 Date: 980622 A/C - Filtering Refrigerant After Compressor Replacement Article No. 98-12-5 06/22/98 AIR CONDITIONING - FILTERING REFRIGERANT AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86 CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII 1995-98-MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150, F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98 EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to revise the Service Procedure and to update the model years. ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the refrigerant system cleaned to remove any debris or contaminants that may be present to prevent damage to the replacement compressor. ACTION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 2050 Install a Service Filter Kit in the refrigerant system prior to installing the replacement compressor. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-15-5 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-99 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models And Major Component Warranty Coverage For All Other Lincoins OPERATION DESCRIPTION TIME 981205A Kit Installation 1.2 Hrs. 981205B Extra Time For Refrigerant 0.4 Hr. (R-12) Recovery DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208999 Service Procedure THIS PROCEDURE IS OPTIONAL IF THE SYSTEM IS FLUSHED USING THE ROTUNDA A/C FLUSHER. CAUTION THIS FILTERING PROCEDURE MAY BE USED FOR EITHER R-12 OR R-134a REFRIGERANT SYSTEMS. BECAUSE THE TWO (2) SYSTEMS USE DIFFERENT REFRIGERANT OILS AND BECAUSE THE COMPRESSOR COULD BE DAMAGED IF THE WRONG OIL IS USED, SYSTEM IDENTIFICATION IS VERY IMPORTANT. BE SURE SYSTEM IS CORRECTLY IDENTIFIED BEFORE STARTING THE FILTERING PROCEDURE. Each Service Filter Kit includes the following items: ^ One (1) Pancake Filter (to be installed in the liquid line between the condenser and the orifice tube) ^ One (1) Instruction Sheet NOTE ON 1993-94 RANGER/EXPLORER VEHICLES, TECHNICIANS MAY EXPERIENCE DIFFICULTY WHEN CONNECTING THE PANCAKE FILTER HOSE FITTINGS TO THE EVAPORATOR INLET WITH THE ORIFICE TUBE INSTALLED. REMOVE THE OFFICE TUBE AND RUN THE SYSTEM FOR 1 HOUR AS DESCRIBED IN THE FILTERING PROCEDURE. REINSTALL THE ORIFICE TUBE AFTER FILTERING IS COMPLETE. CAUTION FOLLOW ALL REFRIGERANT SYSTEM SAFETY AND SERVICE PRECAUTIONS OUTLINED IN THE APPROPRIATE SERVICE OR WORKSHOP MANUAL. 1. Before removing any refrigerant system components, recover the refrigerant from the system following the recycling methods outlined In the appropriate Service/Workshop Manual. 2. Remove the suction accumulator/drier assembly and drain the oil into a calibrated container. 3. Install a new suction accumulator/drier and add new refrigerant oil to replace the old oil. The quantity of the new oil to be added is the amount to match that drained from the old accumulator plus 60 mL (2 oz). Refer to the Dealer Master Parts Catalog for the correct suction accumulator/drier part number. CAUTION REMEMBER TO USE MOTORCRAFT YN-9-A REFRIGERANT COMPRESSOR OIL WITH R-12 SYSTEMS AND MOTORCRAFT YN-12-C REFRIGERANT COMPRESSOR OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. 4. Install a new orifice tube. Refer to the Dealer Master Parts Catalog for the correct orifice tube part number. If the orifice tube in the vehicle is located in the liquid line between the condenser and the evaporator, replace the liquid line assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 2051 5. Install pancake filter in the liquid line between the condenser and the orifice tube, Figure 1. a. Be sure orifice inlet is toward the condenser. b. Connections can be made using Test Adapter Set D93L-19703-B, or equivalent, and flexible refrigerant hose of 2500 psi burst rating. Individual fittings are also available. 6. Remove the old compressor following Service/Workshop Manual procedures. Drain the oil into a calibrated container. 7. Drain the oil from the replacement compressor into a clean calibrated container. NOTE: IT WILL BE NECESSARY TO TRANSFER THE MAGNET CLUTCH FROM THE OLD COMPRESSOR TO THE REPLACEMENT COMPRESSOR. FOLLOW SERVICE/WORKSHOP MANUAL PROCEDURES. 8. A new FX-15 service compressor contains 207 mL (7 oz.) of R-12 refrigerant oil. A new FS-10 service compressor does not contain any oil and can be used with an R-12 or an R-134a system. CAUTION REMEMBER TO USE YN-9-A (MINERAL) OIL WITH R-12 SYSTEMS AND YN-12-C (PAG) OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. ^ If the amount of oil drained from the removed compressor is between 90 and 148 mL (3-5 oz), pour the same amount of clean refrigerant oil into the new compressor. ^ If the amount of oil drained from the old compressor is greater than 90 mL (3 oz), pour 90 mL (3 oz) of clean refrigerant oil into the new compressor. 9. Install the new compressor following Service/Workshop Manual procedures. Make sure all mounting bolts are tightened properly. Check the tension of the compressor drive belt. Adjust if necessary. 10. Evacuate, charge and leak test the system, following Service/Workshop Manual procedures. 11. Check all refrigerant system hoses, lines and the position of the newly-installed filters to make sure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments. 12. Set the A/C control on Max A/C, high blower and temperature control at full cold. a. Start engine and let idle briefly. b. Be sure A/C system is operating properly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 2052 13. Gradually bring the engine up to 1200 rpm by running it at lower rpms for short periods (first at 800 rpm, then at 1000 rpm). Set the engine at 1200 rpm and run it for an hour with the A/C system operating. 14. Stop the engine. NOTE: IT WILL BE NECESSARY TO RECOVER THE SYSTEM REFRIGERANT CHARGE BEFORE PROCEEDING. 15. Allow the engine to cool sufficiently to remove the fittings, flexible hoses and pancake filter from the liquid line. 16. Discard the filter. It can be used one (1) tie only. 17. Reconnect the liquid line back into the system. 18. Evacuate, charge and leak test the system. Make any necessary adjustments. 19. Check the operation of the system in all models. PART NUMBER PART NAME F8VZ-19E773-AA Filter Kit F73Z-19577-AA Refrigerant Oil - Motorcraft YN-9-A (For R-12 Refrigerant Systems Only) F7AZ-19589-DA Refrigerant Oil - Motorcraft YN-12-C (PAG-Type Oil For R-134a Refrigerant Systems Only) NOTE THE TOTAL REPAIR TIME IS FOR INSTALLING SERVICE FILTER KIT PER INSTRUCTIONS THIS INCLUDES INSTALLATION OF AND DISCARD OF FILTER. REFER TO SERVICE LABOR TIME STANDARDS MANUALS IF ADDITIONAL LABOR OPERATIONS ARE REQUIRED. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 2053 Refrigerant: Technical Service Bulletins A/C - R134a Tracer Dye and Three O Ring Spring Couplers Article No. 97-3-5 02/03/97 AIR CONDITIONING - R-134A TRACER DYE INSTALLED IN A/C SYSTEM AND THREE 0-RING SPRING LOCK COUPLERS - SERVICE TIP FORD: 1996-97 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1996-97 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VIII, MYSTIQUE, SABLE, TOWN CAR, TRACER LIGHT TRUCK: 1996 BRONCO 1996-97 AEROSTAR, ECONOLINE, EXPLORER, F-150-350 SERIES, RANGER, WINDSTAR 1997 EXPEDITION, MOUNTAINEER This TSB article is being republished in its entirety to update the text. ISSUE: Ford Motor Company now produces new vehicles with R-134a fluorescent tracer dye incorporated into the A/C system and spring lock couplings which contain three (3) O-rings. ACTION: Leak checking can be performed with the use of a Rotunda UV Lamp (112-R0021) and is an acceptable alternative to using an electronic leak detector. Ford Motor Company has begun implementation of spring lock couplings with three (3) O-rings which provide an improved seal. Field and laboratory tests have shown a 40% improvement in sealing capability and durable life. Through field and fleet testing and analysis, it is apparent that lubricating oil used in vehicle assembly processes is easily misdiagnosed as a refrigerant leak. The presence of oil at connections is not necessarily an indication of a leaking connection. If oil at a fitting is due to a leak, fluorescent tracer dye will be present at the location. Any oil escaping from the A/C hoses will contain dye. When checking for leaks, be sure to scan all components, fittings and lines of the A/C system with the UV lamp. The exact location of the leak or leaks can be pinpointed by the bright yellow-green glow of the tracer dye. Since more than one leak may exist in the system, always inspect each component. The best leak detection results will be achieved in conditions of low ambient light. In areas that cannot be reached by the UV lamp: (1) use a technician's mirror or (2) use a non-fluorescent shop towel, wipe the suspected area, and then check the towel with the UV lamp for traces of the dye. After the leak is repaired, the traces of dye can be removed from the previously leaking areas by using any general purpose oil solvent. Verify the repair by operating the A/C system for a short while and reinspecting the system with the UV lamp. NOTE: BEGINNING WITH VEHICLES PRODUCED IN MAY 1996, THE TRACER DYE'S FLUORESCENT LIFESPAN IS THE LIFE OF THE VEHICLE. VEHICLES PRODUCED BEFORE MAY 1996 CONTAIN A TRACER DYE WITH A LIFESPAN OF ROUGHLY 500 HOURS OF NC SYSTEM USE, AFTER WHICH TIME ANOTHER INFUSION OF DYE WOULD BE REQUIRED. REFER TO TSB 94-26-6 AND 95-21-4 IF ADDITIONAL TRACER DYE OR INFORMATION IS REQUIRED. OTHER APPLICABLE ARTICLES: 94-23-10, 94-26-6, 95-21-4, 96-15-6 SUPERSEDES: 95-21-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200, 208999 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Capacity Capacity With Auxiliary A/C Without Auxiliary A/C Refrigerant Charge 62 oz. 37 oz. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 2056 Refrigerant: Fluid Type Specifications Refrigerant Type .................................................................................................................................. ...................................................................... R-134a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > A/C - Refrigerant Oil Refill Capacity Refrigerant Oil: Technical Service Bulletins A/C - Refrigerant Oil Refill Capacity Article No. 97-15-5 07/21/97 AIR CONDITIONING - OIL REFILL CAPACITY CHART - SERVICE TIP FORD: 1994 TEMPO 1994-97 ASPIRE, PROBE, THUNDERBIRD 1994-98 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1995-98 CONTOUR LINCOLN-MERCURY: 1994 CAPRI, TOPAZ 1994-97 COUGAR 1994-98 CONTINENTAL, GRAND MARQUIS, MARK VIII, SABLE, TOWN CAR, TRACER 1995-98 MYSTIQUE LIGHT TRUCK: 1994-96 BRONCO 1994-97 AEROSTAR 1994-98 ECONOLINE, EXPLORER, F-150-350 SERIES, RANGER, VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: This TSB article will provide an easy and quick reference chart for determining the correct amount of refrigerant oil to use when servicing an A/C system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > A/C - Refrigerant Oil Refill Capacity > Page 2061 ACTION: Refer to Figure 1 to determine how much refrigerant oil is needed to service an A/C system. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200, 208999 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications REFRIGERANT OIL ADDITION During A/C Compressor Replacement A new FS-10 service replacement A/C compressor contains no refrigerant oil. a. If the amount of oil drained from the removed A/C compressor is between 85 and 142 ml (3 oz to 5 oz), pour the same amount plus one ounce of clean oil into the new A/C compressor. b. If the amount of oil drained from the old A/C compressor is greater than 142 ml (5 oz), pour only 142 ml (5 oz) of clean refrigerant oil into the new A/C compressor. c. If the amount of refrigerant oil drained from the old A/C compressor is less than 85 ml (3 oz), pour 85 ml (3 oz) of clean refrigerant oil into the new compressor. During Replacement of A/C Refrigerant Components When replacing components of the air-conditioning refrigerant system, add oil to the replacement components. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 2064 Refrigerant Oil: Fluid Type Specifications PAG Compressor Oil (R-134a System) .................................................................................................................................................... WSH-M1C231-B Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 2065 Refrigerant Oil: Service and Repair DURING A/C COMPRESSOR REPLACEMENT 1. A new FS-10 service replacement A/C compressor contains no refrigerant oil. If the amount of oil drained from the removed A/C compressor is between 85 and 142 ml (3 to 5 oz), pour the same amount plus one ounce of clean oil into the new A/C compressor. If the amount of oil drained from the old A/C compressor is greater than 142 ml (5 oz), pour only 142 ml (5 oz) of clean refrigerant oil into the new A/C compressor. If the amount of refrigerant oil drained from the old A/C compressor is less than 85 ml (3 oz), pour 85 ml (3 oz) of clean refrigerant oil into the new compressor. ^ When replacing components of the air-conditioning refrigerant system, add oil to the replacement components. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure Brake Bleeding: Service and Repair Caliper Bleeding Procedure WARNING: ^ Brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. Wash hands thoroughly after handling. if brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: ^ Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. ^ Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: ^ When any part of the hydraulic system has been disconnected for repair or replacement, air may get in to the system and cause spongy brake pedal action. This requires the bleeding of the affected portions of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment Brake Bleeder. 1. Connect a clear waste line to the affected disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Open the bleeder screw and cycle the brake pedal 25 to 30 times or until no more air is seen at the waste line. Tighten Disc Brake Caliper Bleeder Screw 3. Tighten the disc brake caliper bleeder screw to proper specification. 4. Disconnect the waste line. 5. Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid, C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A, DOT 3. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 2070 Brake Bleeding: Service and Repair Gravity Bleeding WARNING: ^ Brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. Wash hands thoroughly after handling. if brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: ^ Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. ^ Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: ^ When any part of the hydraulic system has been disconnected for repair or replacement, air may get in to the system and cause spongy brake pedal action. This requires the bleeding of the affected portions of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment Brake Bleeder. 1. Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A, DOT 3. 2. Bleed the rear disc brake calipers. a. Place a box end wrench on the RH disc brake caliper bleeder screw. b. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. c. Open the bleeder screw and leave open until clear bubble-free brake fluid flows. d. Repeat for LH rear disc brake caliper. 3. Tighten the rear disc brake caliper bleeder screws. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 2071 4. Bleed the front disc brake calipers. a. Place a box end wrench on the RH front disc brake caliper bleeder screw. b. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. c. Open the bleeder screw and leave open until clear bubble-free brake fluid flows. d. Repeat for LH front disc brake caliper. 5. Tighten the front disc brake caliper bleeder screws. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 2072 Brake Bleeding: Service and Repair Manual Bleeding WARNING: ^ Brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. Wash hands thoroughly after handling. if brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: ^ Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. ^ Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: ^ When any part of the hydraulic system has been disconnected for repair or replacement, air may get in to the system and cause spongy brake pedal action. This requires the bleeding of the affected portions of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment Brake Bleeder. 1. Place a box end wrench on the RH rear disc brake caliper bleeder screw. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Have an assistant pump the brake pedal 10 times and then hold firm pressure on the brake pedal. 3. Loosen the RH rear disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH rear disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 4. Tighten the RH rear disc brake caliper bleeder screw. 5. Repeat steps 1, 2, 3, and 4 for the LH rear disc brake caliper. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 2073 6. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 7. Have an assistant pump the brake pedal 10 times and then hold firm pressure on the brake pedal. 8. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH front disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 9. Tighten the RH front disc brake caliper bleeder screw. 10. Repeat steps 6, 7, 8, and 9 for the LH front disc brake caliper bleeder screw. 11. If necessary, bleed the brake master cylinder. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 2074 Brake Bleeding: Service and Repair Master Cylinder Bleeding WARNING: ^ brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: ^ Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. ^ Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: ^ When any part of the hydraulic system has been disconnected for repair or replacement, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment Brake Bleeder. 1. Support the brake master cylinder body in a vise and fill the brake master cylinder reservoir with specified brake fluid. ^ Use High Performance DOT 3 Brake Fluid C6AZ-19S42-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A, DOT 3. 2. Install plugs in the front and rear brake outlet ports. Bleed the front brake system first. Loosen Plug 3. Loosen the plug in the front outlet port and slowly depress the primary piston. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 2075 Tighten Plug 4. Tighten the plug in the front outlet port and release the primary piston. 5. Repeat this procedure until clear, bubble-free brake fluid flows. 6. Repeat steps 3, 4, and 5 for the rear outlet port with the front outlet port plugged. 7. Tighten the plugs and try to depress the primary piston. The piston will not depress if all the air is out of the system. 8. Install the brake master cylinder filler cap and install the brake master cylinder in the vehicle. 9. Bleed the system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 2076 Brake Bleeding: Service and Repair Caliper Bleeding Procedure WARNING: ^ Brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. Wash hands thoroughly after handling. if brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: ^ Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. ^ Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: ^ When any part of the hydraulic system has been disconnected for repair or replacement, air may get in to the system and cause spongy brake pedal action. This requires the bleeding of the affected portions of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment Brake Bleeder. 1. Connect a clear waste line to the affected disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Open the bleeder screw and cycle the brake pedal 25 to 30 times or until no more air is seen at the waste line. Tighten Disc Brake Caliper Bleeder Screw 3. Tighten the disc brake caliper bleeder screw to proper specification. 4. Disconnect the waste line. 5. Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid, C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A, DOT 3. Gravity Bleeding WARNING: ^ Brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. Wash hands thoroughly after handling. if brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: ^ Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 2077 ^ Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: ^ When any part of the hydraulic system has been disconnected for repair or replacement, air may get in to the system and cause spongy brake pedal action. This requires the bleeding of the affected portions of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment Brake Bleeder. 1. Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A, DOT 3. 2. Bleed the rear disc brake calipers. a. Place a box end wrench on the RH disc brake caliper bleeder screw. b. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. c. Open the bleeder screw and leave open until clear bubble-free brake fluid flows. d. Repeat for LH rear disc brake caliper. 3. Tighten the rear disc brake caliper bleeder screws. 4. Bleed the front disc brake calipers. a. Place a box end wrench on the RH front disc brake caliper bleeder screw. b. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. c. Open the bleeder screw and leave open until clear bubble-free brake fluid flows. d. Repeat for LH front disc brake caliper. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 2078 5. Tighten the front disc brake caliper bleeder screws. Manual Bleeding WARNING: ^ Brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. Wash hands thoroughly after handling. if brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: ^ Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. ^ Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: ^ When any part of the hydraulic system has been disconnected for repair or replacement, air may get in to the system and cause spongy brake pedal action. This requires the bleeding of the affected portions of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment Brake Bleeder. 1. Place a box end wrench on the RH rear disc brake caliper bleeder screw. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Have an assistant pump the brake pedal 10 times and then hold firm pressure on the brake pedal. 3. Loosen the RH rear disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH rear disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 4. Tighten the RH rear disc brake caliper bleeder screw. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 2079 5. Repeat steps 1, 2, 3, and 4 for the LH rear disc brake caliper. 6. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 7. Have an assistant pump the brake pedal 10 times and then hold firm pressure on the brake pedal. 8. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH front disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 9. Tighten the RH front disc brake caliper bleeder screw. 10. Repeat steps 6, 7, 8, and 9 for the LH front disc brake caliper bleeder screw. 11. If necessary, bleed the brake master cylinder. Master Cylinder Bleeding WARNING: ^ brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: ^ Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. ^ Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: ^ When any part of the hydraulic system has been disconnected for repair or replacement, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment Brake Bleeder. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 2080 1. Support the brake master cylinder body in a vise and fill the brake master cylinder reservoir with specified brake fluid. ^ Use High Performance DOT 3 Brake Fluid C6AZ-19S42-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A, DOT 3. 2. Install plugs in the front and rear brake outlet ports. Bleed the front brake system first. Loosen Plug 3. Loosen the plug in the front outlet port and slowly depress the primary piston. Tighten Plug 4. Tighten the plug in the front outlet port and release the primary piston. 5. Repeat this procedure until clear, bubble-free brake fluid flows. 6. Repeat steps 3, 4, and 5 for the rear outlet port with the front outlet port plugged. 7. Tighten the plugs and try to depress the primary piston. The piston will not depress if all the air is out of the system. 8. Install the brake master cylinder filler cap and install the brake master cylinder in the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 2081 9. Bleed the system. Pressure Bleeding WARNING: ^ Brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. Wash hands thoroughly after handling. if brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: ^ Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. ^ Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: ^ When any part of the hydraulic system has been disconnected for repair or replacement, air may get in to the system and cause spongy brake pedal action. This requires the bleeding of the affected portions of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment Brake Bleeder. ^ Bleed the longest line first. Be sure the bleeder tank contains enough specified brake fluid to complete the bleeding operation. 1. Clean all dirt from and remove the (A) brake master cylinder filler cap and fill the (B) brake master cylinder reservoir with the specified brake fluid. 2. Install Brake Bleeder to the brake master cylinder reservoir and attach the bleeder tank hose to the fitting on the adapter. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers of pressure bleeding equipment. Follow the instructions of the manufacturer when installing the adapter. 3. Place a box end wrench on the RH rear disc brake caliper bleeder screw. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 4. Open the valve on the bleeder tank. 5. Open the rear disc brake caliper bleeder screw. Leave open until clear, bubble-free brake fluid flows, then close rear disc brake caliper bleeder screw and remove the rubber hose. 6. Continue bleeding the rest of the system, going in order from the LH rear disc brake caliper to the RH front disc brake caliper ending with the LH front disc brake caliper. 7. Close the bleeder tank valve and remove the tank hose from the adapter and remove the adapter. 8. Fill the (A) brake master cylinder reservoir and install the (B) brake master cylinder filler cap. 4 Wheel Anti-Lock Brakes (4WABS) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 2082 WARNING: ^ Brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. Wash hands thoroughly after handling. if brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. get medical attention immediately. CAUTION: ^ Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. ^ Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: ^ When any part of the hydraulic system has been disconnected for repair or replacement, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment Brake Bleeder. ^ This procedure only needs to be performed if the 4 Wheel Anti-lock Brake System (4WABS) Hydraulic Control Unit (HCU) has been replaced. ^ One conventional pressure bleed cycle consists of advancing the brake pedal to its depressed position, opening the rear disc brake caliper bleeder screw, allowing fluid to be released into the waste container, closing the rear disc brake caliper bleeder screw and releasing the brake pedal to its full upright position. ^ Performing the New Generation Star (NGS) program routine drives entrapped air from the otherwise inaccessible lower section of the 4WABS valve into the upper sections (accessible by bleeding the brakes). Subsequent bleedings remove the air from the system. ^ Add recommended brake fluid as necessary throughout the procedure. PROCEDURE 1. Connect a clear waste line to the RH rear disc brake caliper bleeder screw and the other end in a container partially filled with recommended brake fluid. 2. With the RH rear disc brake caliper bleeder screw open, cycle the brake pedal until no more air is seen in the waste line. 3. Close the RH rear disc brake caliper bleeder screw and disconnect the waste line. 4. Repeat steps 1, 2, and 3 for the LH rear disc brake caliper bleeder screw, RH front disc brake caliper bleeder screw, and the LH front disc brake caliper bleeder screw. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 2083 Connect Cable Adapter 5. Connect the (A) NGS DCL cable adapter into the (B) vehicle data link connector (DLC). 6. Select VEHICLE AND ENGINE SELECTION and press trigger to start the NGS. 7. Select SELECT NEW VEHICLE YEAR AND MODEL and press trigger to start the NGS. 8. Select the appropriate vehicle year application and press trigger to start the NGS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 2084 9. Scroll down to the appropriate vehicle application and highlight and trigger to start the NGS. 10. The NGS will prompt you to verify correct application. Trigger the NGS if correct. 11. Select DIAGNOSTIC DATA LINK and press trigger to start the NGS. 12. Follow the NGS prompt PRESS TRIGGER TO CONTINUE or PRESS CANCEL TO BYPASS. 13. Select ABS ANTI-LOCK BRAKE MODULE and press trigger to start the NGS. 14. Select FUNCTION TESTS and press trigger to start the NGS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 2085 15. Select SERVICE BLEED FUNCTION and press trigger to start the NGS. 16. Select PRESS TRIGGER TO BEGIN. NOTE: The brake pedal should be depressed while this procedure is functioning. Perform at least five service bleed procedures. 17. Repeat conventional bleed procedure as outlined in steps 1 through 4. 18. If brake pedal feels spongy, repeat NGS service bleed procedure as outlined in steps 5 through 16 and repeat conventional bleed steps 1 through 4. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming Deactivation Procedure 1. Disconnect positive battery cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Wait one minute. This is the time required for backup power supply in air bag diagnostic monitor to deplete its stored energy. 3. Remove two back cover plugs and remove screw and washer assemblies retaining driver side air bag module to steering wheel. Disconnect horn electrical connector. Disconnect driver air bag sliding contact electrical connector. Remove driver side air bag module from vehicle. WARNING: Place air bag module on bench with trim cover facing up. 4. Connect Rotunda Air Bag Simulator 105-R0011 or equivalent to vehicle harness at top of steering column. 5. Remove passenger side air bag module. Install Rotunda Air Bag Simulator 105-00012 or equivalent on vehicle harness connector in place of passenger side air bag module. 6. Reconnect positive battery cable. Reactivation Procedure 1. Disconnect positive battery cable. WARNING: The air bag simulator must be removed and the air bag reconnected when the system is reactivated. 2. Wait one minute for backup power supply in air bag diagnostic monitor to deplete stored energy. 3. Remove air bag simulator from vehicle harness connector at top of steering column. 4. Reconnect driver side air bag module. 5. Position driver side air bag module on steering wheel and secure with two screw and washer assemblies (8 mm). Tighten screw and washer assemblies to 10-13 Nm (89-115 lb in). Install two back cover plugs. 6. Remove air bag simulator from vehicle harness connector on passenger side. Reconnect and install passenger side air bag module. 7. Reconnect positive battery cable. 8. Prove out system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 2090 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The check list below should be completed following diagnosis or service of any air bag system concern: 1. Are both air bag crash sensors connected and mounted to the vehicle? 2. Is 3-way connector at base of steering column connected? 3. Are the air bags or air bag simulators connected? 4. Is air bag diagnostic monitor connected? 5. Is vehicle battery connected? Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2096 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2097 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2098 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2099 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2100 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2101 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2102 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2103 Fuse: Electrical Diagrams Circuit-to-Fuse Cross Reference Compact Disc Changer ....................................................................................................................... ......................................................................... Fuse 3 Powertrain Control Module ............................ ............................................................................................................................................................. Fuse 1 Premium Sound Amplifier ........................................................................................................ ................................................................................... Fuse 5 Radio ................................................... .............................................................................................................................................................. .......... Fuse 3 Rear Integrated Control Panel ...................................................................................... ................................................................................................ Fuse 3 Sub-Woofer Power ................. .............................................................................................................................................................. ....................... Fuse 5 Trailer Tow Left Turn Relay ............................................................................. .......................................................................................................... Fuse 2 Trailer Tow Right Turn Relay ................................................................................................................................................... .................................. Fuse 2 Fuse 1 Fuse 1 - protects the following circuits: ^ Powertrain Control Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2104 Power Distribution Fuse 2 Fuse 2 - protects the following circuits: ^ Trailer Tow Left Turn Relay ^ Trailer Tow Right Turn Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2105 Power Distribution Fuse 3 Fuse 3 - protects the following circuits: ^ Radio ^ Rear Integrated Control Panel ^ Compact Disc Changer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2106 Power Distribution Fuse 5 Fuse 5 - protects the following circuits: ^ Sub-Woofer Power ^ Premium Sound Amplifier Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2107 Power Distribution Circuit-to-Fuse Cross Reference 4 Wheel Air Suspension Module ......................................................................................................... ........................................................................ Fuse 6 4 Wheel Air Suspension ................................. ........................................................................................................................................................... Fuse 20 4 Wheel Anti-Lock Brake System Module ............................................................................. ................................................................................... Fuse 25 4 Wheel Anti-Lock Brake System Relay ................................................................................................................................................... ................ Fuse 25 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2108 4X4 Center Axle Disconnect Solenoid ................................................................................................. ..................................................................... Fuse 23 Air Bag Diagnostic Monitor .............................. ............................................................................................................................................... Fuse 19 & 22 Autolamp Module ........................................................................................................................ ....................................................................... Fuse 4 & 29 Auxiliary A/C Control Module .................. .............................................................................................................................................................. . Fuse 23 Auxiliary A/C Mode Actuator ................................................................................................ ................................................................................... Fuse 23 Auxiliary A/C Relay ............................ .............................................................................................................................................................. .......... Fuse 7 Battery Saver Relay ...................................................................................................... ............................................................................................. Fuse 14 Blend Door Actuator ................ .............................................................................................................................................................. ..................... Fuse 5 Brake On/Off Switch .......................................................................................... ....................................................................................................... Fuse 13 Brake Pressure Switch .. .............................................................................................................................................................. ............................... Fuse 13 Cigar Lighter .......................................................................................... ...................................................................................................................... Fuse 3 Coil On Plugs .... .............................................................................................................................................................. ........................................... Fuse 30 Compass Sensor ....................................................................... .................................................................................................................................... Fuse 6 Console Blower Motor ......................................................................................................................... ....................................................................... Fuse 7 Data Link Connector ........................................ .......................................................................................................................................................... Fuse 12 Daytime Running Lamps Module .......................................................................................... ........................................................................ Fuse 5,16 & 26 Digital Transmission Range Sensor .. .............................................................................................................................................................. .... Fuse 5 & 21 Electronic Variable Orifice Module ............................................................................. ............................................................................................... Fuse 5 Flasher Relay .......................... .............................................................................................................................................................. ....................... Fuse 1 Fog Lamp Relay .............................................................................................. ........................................................................................................... Fuse 27 Function Selector Switch .................................................................................................................................................. ................................ Fuse 23 & 24 Generic Electronic Module ........................................................... ............................................................................................................ Fuse 6,18,15 & 20 Headlamp Relay ................................................................................................................................................... ........................................................ Fuse 4 Heated Backlight Switch ................................................. ........................................................................................................................................... Fuse 17 Heated Grid Relay ............................................................................................................................... ........................................................................ Fuse 6 Heater-A/C Control Assembly ........................ ............................................................................................................................................................. Fuse 5 High Beam Headlamps ............................................................................................................ .................................................................................. Fuse 16 Ignition Coil ......................................... .............................................................................................................................................................. ........ Fuse 30 Instrument Cluster ........................................................................................................ .................................................................................. Fuse 2,19 & 29 Instrument Cluster (Without Daytime Running Lamps) ............................................................................................................................................ Fuse 16 Instrument Illumination ........................................................................................................................ ...................................................................... Fuse 18 Interior Lamp Relay ........................................ ........................................................................................................................................................... Fuse 14 Junction Box Fuse/Relay Panel ............................................................................................. .................................................................................... Fuse 21 Junction Box Fuse Relay Panel Fuse 20 ......................................................................................................................................................... ........... Fuse 21 Left Headlamp ........................................................................................................... ................................................................................................ Fuse 28 Left Power/Heated Signal Mirror ................................................................................................................................................... ........................... Fuse 17 Main Light Switch ...................................................................................... ................................................................................................... Fuse 8,18 & 27 Overhead Trip Computer Module ................................................................................................................................ ......................................... Fuse 2 & 6 PCM Power Diode ................................................................... .................................................................................................................................. Fuse 30 Park Lamp Relay ......................................................................................................................................... ................................................................ Fuse 4 Passive Anti-Theft System Module ......................... .................................................................................................................................................. Fuse 15 Power Mirror Switch ....................................................................................................................... ............................................................................ Fuse 4 Radio Noise Capacitor ................................ .............................................................................................................................................................. . Fuse 30 Radio ................................................................................................................................... ........................................................................................ Fuse 8 Rear Integrated Control Panel ........ .............................................................................................................................................................. .............. Fuse 23 Rear Wiper Pump Relay ......................................................................................... ................................................................................................... Fuse 11 Recirculation Vacuum Solenoid ............................................................................................................................................... ................................. Fuse 23 Remote Anti-Theft Personality Module ................................................ ................................................................................................................ Fuse 4 & 8 Right Headlamp .............................................................................................................................................................. ........................................... Fuse 26 Right Power/Heated Signal Mirror ............................................. ............................................................................................................................... Fuse 17 Shift Lock Actuator ............................................................................................................................................... ...................................................... Fuse 6 Speed Control Servo/Amplifier Assembly ......................... .......................................................................................................................................... Fuse 5 Steering Wheel Rotation Sensor ......................................................................................................... ......................................................................... Fuse 6 Trailer Tow Battery Charge Relay ................. ............................................................................................................................................................ Fuse 23 Transmission Control Switch ................................................................................................. .................................................................................... Fuse 29 Washer Pump Relay ......................... .............................................................................................................................................................. ............ Fuse 11 Windshield Wiper Motor ........................................................................................... ................................................................................................ Fuse 11 Wiper High/Low Relay .......... .............................................................................................................................................................. ...................... Fuse 11 Wiper Run/Park Relay .................................................................................... ........................................................................................................... Fuse 11 Fuse 1 Fuse 1 - protects the following circuits: ^ Flasher Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2109 Power Distribution Fuse 2 Fuse 2 - protects the following circuits: ^ Instrument Cluster ^ Overhead Trip Computer Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2110 Power Distribution Fuse 3 Fuse 3 - protects the following circuits: ^ Cigar Lighter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2111 Power Distribution Fuse 4 Fuse 4 - protects the following circuits: ^ Park Lamp Relay ^ Headlamp Relay ^ Autolamp Module ^ Remote Anti-Theft Personality Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2112 ^ Power Mirror Switch Power Distribution Fuse 5 Fuse 5 - protects the following circuits: ^ Digital Transmission Range Sensor ^ Daytime Running Lamps Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2113 ^ Speed Control Servo/Amplifier Assembly ^ Heater-A/C Control Assembly ^ Blend Door Actuator ^ Electronic Variable Orifice Module Power Distribution Fuse 6 Fuse 6 - protects the following circuits: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2114 ^ Shift Lock Actuator ^ Generic Electronic Module ^ 4 Wheel Air Suspension Module ^ Compass Sensor ^ Steering Wheel Rotation Sensor ^ Heated Grid Relay ^ Overhead Trip Computer Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2115 Power Distribution Power Distribution Fuse 7 Fuse 7 - protects the following circuits: ^ Auxiliary A/C Relay ^ Console Blower Motor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2116 Power Distribution Fuse 8 Fuse 8 - protects the following circuits: ^ Radio ^ Main Light Switch ^ Remote Anti-Theft Personality Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2117 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2118 Power Distribution Fuse 11 Fuse 11 - protects the following circuits: ^ Washer Pump Relay ^ Wiper Run/Park Relay ^ Wiper High/Low Relay ^ Windshield Wiper Motor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2119 ^ Rear Wiper Pump Relay Power Distribution Fuse 12 Fuse 12 - protects the following circuits: ^ Data Link Connector Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2120 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: ^ Brake On/Off Switch ^ Brake Pressure Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2121 Power Distribution Fuse 14 Fuse 14 - protects the following circuits: ^ Battery Saver Relay ^ Interior Lamp Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2122 Power Distribution Fuse 15 Fuse 15 - protects the following circuits: ^ Generic Electronic Module ^ Passive Anti-Theft System Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2123 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: ^ Instrument Cluster (Without Daytime Running Lamps) ^ Daytime Running Lamps Module ^ High Beam Headlamps Power Source Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2124 Power is Supplied Through Multi-Function Switch Power Distribution Fuse 17 Fuse 17 - protects the following circuits: ^ Heated Backlight Switch ^ Left Power/Heated Signal Mirror Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2125 ^ Right Power/Heated Signal Mirror Power Distribution Fuse 18 Fuse 18 - protects the following circuits: ^ Main Light Switch ^ Generic Electronic Module ^ Instrument Illumination Power Source Power is Supplied Through Main Light Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2126 Power Distribution Fuse 19 Fuse 19 - protects the following circuits: ^ Instrument Cluster ^ Air Bag Diagnostic Monitor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2127 Power Distribution Fuse 20 Fuse 20 - protects the following circuits: ^ 4 Wheel Air Suspension ^ Generic Electronic Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2128 Power Distribution Fuse 21 Fuse 21 - protects the following circuits: ^ Digital Transmission Range Sensor ^ Junction Box Fuse/Relay Panel Fuse 20 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2129 Power Distribution Fuse 22 Fuse 22 - protects the following circuits: ^ Air Bag Diagnostic Monitor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2130 Power Distribution Fuse 23 Fuse 23 - protects the following circuits: ^ Trailer Tow Battery Charge Relay ^ 4X4 Center Axle Disconnect Solenoid Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2131 ^ Function Selector Switch ^ Rear Integrated Control Panel ^ Recirculation Vacuum Solenoid ^ Auxiliary A/C Mode Actuator ^ Auxiliary A/C Control Module Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2132 Fuse 24 Fuse 24 - protects the following circuits: ^ Function Selector Switch Power Distribution Fuse 25 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2133 Fuse 25 - protects the following circuits: ^ 4 Wheel Anti-Lock Brake System Module ^ 4 Wheel Anti-Lock Brake System Relay Power Distribution Fuse 26 Fuse 26 - protects the following circuits: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2134 ^ Daytime Running Lamps Module ^ Right Headlamp Power Source Power is Supplied Through Multi-Function Switch Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2135 Fuse 27 Fuse 27 - protects the following circuits: ^ Main Light Switch ^ Fog Lamp Relay Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2136 Fuse 28 Fuse 28 - protects the following circuits: ^ Left Headlamp Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2137 Fuse 29 Fuse 29 - protects the following circuits: ^ Autolamp Module ^ Instrument Cluster ^ Transmission Control Switch Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2138 Fuse 30 Fuse 30 - protects the following circuits: ^ Radio Noise Capacitor ^ Ignition Coil ^ PCM Power Diode ^ Coil On Plugs Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2139 Power Distribution Circuit-to-Fuse Cross Reference 4 Wheel Anti-Lock Brake System Module ........................................................................................... ..................................................................... Fuse 14 Accessory Delay Relay .................................... .......................................................................................................................................................... Fuse 25 Air Bag Diagnostic Monitor .................................................................................................... .................................................................................... Fuse 2 Air Suspension Service Switch ........... .............................................................................................................................................................. ........... Fuse 4 Air Suspension Solid State Compressor Relay .......................................................................................................................................................... Fuse 15 All Lock Relays ...................................................................................................................... ..................................................................................... Fuse 3 All Unlock Relays ............................... .............................................................................................................................................................. ........... Fuse 3 Auxiliary A/C Relay ...................................................................................................... ............................................................................................ Fuse 13 Compact Disc Changer ............ .............................................................................................................................................................. ...................... Fuse 6 Console Auxiliary Power Socket ....................................................................... ........................................................................................................ Fuse 11 Daytime Running Lamps Module ..................................................................................................................................... ........................................... Fuse 9 Drover's Unlock Relay ................................................................. ................................................................................................................................ Fuse 3 Engine Fuse Module (Fuse 1) ......................................................................................................................... ........................................................... Fuse 24 Engine Fuse Module (Fuse 2) ................................... ................................................................................................................................................. Fuse 16 Engine Fuse Module (Fuse 3) ........................................................................................................ .............................................................................. Fuse 6 Engine Fuse Module (Fuse 5) .................. .............................................................................................................................................................. ...... Fuse 6 Flip Window Relay ............................................................................................................ ........................................................................................ Fuse 29 Fog Lamp Relay ........................... .............................................................................................................................................................. .................. Fuse 9 Fuel Pump Relay .................................................................................................. ...................................................................................................... Fuse 19 Headlamp Relay ............. .............................................................................................................................................................. ................................ Fuse 8 Heated Grid Relay .................................................................................. ................................................................................................................... Fuse 27 Horn Relay ......... .............................................................................................................................................................. ............................................ Fuse 5 Hybrid Cooling Fan Relay ........................................................... .............................................................................................................................. Fuse 29 Ignition Switch .................................................................................................................................................. ................................................ Fuse 20 & 21 Instrument Panel (I/P) Auxiliary Power Socket ......................................................................................................................................................... Fuse 10 I/P Blower Relay .................................................................................................................... .................................................................................... Fuse 23 Junction Box Fuse/Relay Panel Battery Feed ............................................................................................................................................................ Fuse 22 Junction Box Fuse/Relay Panel ............................................................................................. ........................................................................... Fuse 25 & 27 Main Light Switch .............................. .............................................................................................................................................................. .... Fuse 7 & 8 Multi-Function Switch ................................................................................................... .............................................................................................. Fuse 8 Park Lamp Relay ...................... .............................................................................................................................................................. ..................... Fuse 7 PCM Power Relay ............................................................................................. ........................................................................................................ Fuse 24 Power Seat Control Switch .................................................................................................................................................. ...................................... Fuse 18 Premium Sound Amplifier ............................................................... ............................................................................................................................ Fuse 6 Radio .......... .............................................................................................................................................................. ................................................... Fuse 6 Rear Integrated Control Panel ............................................. ......................................................................................................................................... Fuse 6 Rear Wiper Down Motor Relay ..................................................................................................................... ............................................................ Fuse 12 Rear Wiper Up Motor Relay ..................................... ................................................................................................................................................. Fuse 12 Shift On The Fly Relay ................................................................................................................... ........................................................................... Fuse 17 Sub-Woofer Power .................................... .............................................................................................................................................................. .... Fuse 6 Trailer Electronic Brake Controller ...................................................................................... ..................................................................................... Fuse 28 Trailer Tow Backup Lamp Relay ..... .............................................................................................................................................................. ............. Fuse 1 Trailer Tow Battery Charge Relay ............................................................................. ................................................................................................ Fuse 16 Trailer Tow Running Lamp Relay ................................................................................................................................................... ............................ Fuse 1 Transfer Case Shift Relay .......................................................................... ................................................................................................................ Fuse 17 Fuse 1 Fuse 1 - protects the following circuits: ^ Trailer Tow Running Lamp Relay ^ Trailer Tow Backup Lamp Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2140 Power Distribution Fuse 2 Fuse 2 - protects the following circuits: ^ Air Bag Diagnostic Monitor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2141 Power Distribution Fuse 3 Fuse 3 - protects the following circuits: ^ All Unlock Relay ^ All Lock Relay ^ Driver's Unlock Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2142 Power Distribution Fuse 4 Fuse 4 - protects the following circuits: ^ Air Suspension Service Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2143 Power Distribution Fuse 5 Fuse 5 - protects the following circuits: ^ Horn Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2144 Power Distribution Fuse 6 Fuse 6 - protects the following circuits: ^ Radio ^ Premium Sound Amplifier ^ Compact Disc Changer ^ Rear Integrated Control Panel Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2145 ^ Engine Fuse Module Fuse 3 ^ Engine Fuse Module Fuse 5 ^ Sub-Woofer Power Power Distribution Fuse 7 Fuse 7 - protects the following circuits: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2146 ^ Main Light Switch ^ Park Lamp Relay Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2147 Power Distribution Fuse 8 Fuse 8 - protects the following circuits: ^ Main Light Switch ^ Headlamp Relay ^ Multi-function Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2148 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2149 Power Distribution Fuse 9 Fuse 9 - protects the following circuits: ^ Daytime Running Lamps Module ^ Fog Lamp Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2150 Power Distribution Fuse 10 Fuse 10 - protects the following circuits: ^ Instrument Panel Auxiliary Power Socket Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2151 Power Distribution Fuse 11 Fuse 11 - protects the following circuits: ^ Console Auxiliary Power Socket Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2152 Power Distribution Fuse 12 Fuse 12 - protects the following circuits: ^ Rear Wiper Up Motor Relay ^ Rear Wiper Down Motor Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2153 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: ^ Auxiliary A/C Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2154 Power Distribution Fuse 14 Fuse 14 - protects the following circuits: ^ 4 Wheel Anti-Lock Brake System Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2155 Power Distribution Fuse 15 Fuse 15 - protects the following circuits: ^ Air Suspension Solid State Compressor Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2156 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: ^ Trailer Tow Battery Charge Relay ^ Engine Fuse Module Fuse 2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2157 Power Distribution Fuse 17 Fuse 17 - protects the following circuits: ^ Shift On The Fly Relay ^ Transfer Case Shift Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2158 Power Distribution Fuse 18 Fuse 18 - protects the following circuits: ^ Power Seat Control Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2159 Power Distribution Fuse 19 Fuse 19 - protects the following circuits: ^ Fuel Pump Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2160 Power Distribution Fuse 20 Fuse 20 - protects the following circuits: ^ Ignition Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2161 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2162 Power Distribution Fuse 21 Fuse 21 - protects the following circuits: ^ Ignition Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2163 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2164 Power Distribution Fuse 22 Fuse 22 - protects the following circuits: ^ Junction Box Fuse/Relay Panel Battery Feed Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2165 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2166 Power Distribution Fuse 23 Fuse 23 - protects the following circuits: ^ Instrument Panel Blower Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2167 Power Distribution Fuse 24 Fuse 24 - protects the following circuits: ^ PCM Power Relay ^ Engine Fuse Module Fuse 1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2168 Power Distribution Fuse 25 Fuse 25 - protects the following circuits: ^ Junction Box Fuse/Relay Panel ^ Accessory Delay Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2169 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2170 Power Distribution Fuse 27 Fuse 27 - protects the following circuits: ^ Junction Box Fuse/Relay Panel ^ Heated Grid Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2171 Power Distribution Fuse 28 Fuse 28 - protects the following circuits: ^ Trailer Electronic Brake Controller Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2172 Power Distribution Fuse 29 Fuse 29 - protects the following circuits: ^ Flip Window Relay ^ Hybrid Cooling Fan Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2173 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Engine Fuse Module Fuse Block: Locations Engine Fuse Module Engine View The Engine Fuse Module is located near the power distribution box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Engine Fuse Module > Page 2178 Fuse Block: Locations Junction Box/Fuse Relay Panel Junction Box Fuse/Relay Panel (Part 1 Of 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Engine Fuse Module > Page 2179 Instrument Panel View The Junction Box/Fuse Relay Panel is located under left side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2182 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2183 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2184 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2185 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2186 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2187 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2188 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2189 Fuse Block: Connector Views Junction Box/Fuse Panel (C243) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2190 Junction Box/Fuse Panel (C242) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2191 Fuse Block: Electrical Diagrams Circuit-to-Fuse Cross Reference 4 Wheel Anti-Lock Brake System Module ........................................................................................... ..................................................................... Fuse 14 Accessory Delay Relay .................................... .......................................................................................................................................................... Fuse 25 Air Bag Diagnostic Monitor .................................................................................................... .................................................................................... Fuse 2 Air Suspension Service Switch ........... .............................................................................................................................................................. ........... Fuse 4 Air Suspension Solid State Compressor Relay .......................................................................................................................................................... Fuse 15 All Lock Relays ...................................................................................................................... ..................................................................................... Fuse 3 All Unlock Relays ............................... .............................................................................................................................................................. ........... Fuse 3 Auxiliary A/C Relay ...................................................................................................... ............................................................................................ Fuse 13 Compact Disc Changer ............ .............................................................................................................................................................. ...................... Fuse 6 Console Auxiliary Power Socket ....................................................................... ........................................................................................................ Fuse 11 Daytime Running Lamps Module ..................................................................................................................................... ........................................... Fuse 9 Drover's Unlock Relay ................................................................. ................................................................................................................................ Fuse 3 Engine Fuse Module (Fuse 1) ......................................................................................................................... ........................................................... Fuse 24 Engine Fuse Module (Fuse 2) ................................... ................................................................................................................................................. Fuse 16 Engine Fuse Module (Fuse 3) ........................................................................................................ .............................................................................. Fuse 6 Engine Fuse Module (Fuse 5) .................. .............................................................................................................................................................. ...... Fuse 6 Flip Window Relay ............................................................................................................ ........................................................................................ Fuse 29 Fog Lamp Relay ........................... .............................................................................................................................................................. .................. Fuse 9 Fuel Pump Relay .................................................................................................. ...................................................................................................... Fuse 19 Headlamp Relay ............. .............................................................................................................................................................. ................................ Fuse 8 Heated Grid Relay .................................................................................. ................................................................................................................... Fuse 27 Horn Relay ......... .............................................................................................................................................................. ............................................ Fuse 5 Hybrid Cooling Fan Relay ........................................................... .............................................................................................................................. Fuse 29 Ignition Switch .................................................................................................................................................. ................................................ Fuse 20 & 21 Instrument Panel (I/P) Auxiliary Power Socket ......................................................................................................................................................... Fuse 10 I/P Blower Relay .................................................................................................................... .................................................................................... Fuse 23 Junction Box Fuse/Relay Panel Battery Feed ............................................................................................................................................................ Fuse 22 Junction Box Fuse/Relay Panel ............................................................................................. ........................................................................... Fuse 25 & 27 Main Light Switch .............................. .............................................................................................................................................................. .... Fuse 7 & 8 Multi-Function Switch ................................................................................................... .............................................................................................. Fuse 8 Park Lamp Relay ...................... .............................................................................................................................................................. ..................... Fuse 7 PCM Power Relay ............................................................................................. ........................................................................................................ Fuse 24 Power Seat Control Switch .................................................................................................................................................. ...................................... Fuse 18 Premium Sound Amplifier ............................................................... ............................................................................................................................ Fuse 6 Radio .......... .............................................................................................................................................................. ................................................... Fuse 6 Rear Integrated Control Panel ............................................. ......................................................................................................................................... Fuse 6 Rear Wiper Down Motor Relay ..................................................................................................................... ............................................................ Fuse 12 Rear Wiper Up Motor Relay ..................................... ................................................................................................................................................. Fuse 12 Shift On The Fly Relay ................................................................................................................... ........................................................................... Fuse 17 Sub-Woofer Power .................................... .............................................................................................................................................................. .... Fuse 6 Trailer Electronic Brake Controller ...................................................................................... ..................................................................................... Fuse 28 Trailer Tow Backup Lamp Relay ..... .............................................................................................................................................................. ............. Fuse 1 Trailer Tow Battery Charge Relay ............................................................................. ................................................................................................ Fuse 16 Trailer Tow Running Lamp Relay ................................................................................................................................................... ............................ Fuse 1 Transfer Case Shift Relay .......................................................................... ................................................................................................................ Fuse 17 Fuse 1 - Trailer Backup and Running Lamp Relays Fuse 1 - protects the following circuits: ^ Trailer Tow Running Lamp Relay ^ Trailer Tow Backup Lamp Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2192 Power Distribution Fuse 2 - Air Bag Diagnostic Monitor Fuse 2 - protects the following circuits: ^ Air Bag Diagnostic Monitor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2193 Power Distribution Fuse 3 - All Unlock/Lock Relays, Drivers' Unlock Relay Fuse 3 - protects the following circuits: ^ All Unlock Relay ^ All Lock Relay ^ Driver's Unlock Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2194 Power Distribution Fuse 4 - Air Suspension Service Switch Fuse 4 - protects the following circuits: ^ Air Suspension Service Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2195 Power Distribution Fuse 5 - Horn Relay Fuse 5 - protects the following circuits: ^ Horn Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2196 Power Distribution Fuse 6 - Var. Sound Sys. Components, Eng. Fuse Mdl Fuses 3 & 5 Fuse 6 - protects the following circuits: ^ Radio ^ Premium Sound Amplifier ^ Compact Disc Changer ^ Rear Integrated Control Panel Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2197 ^ Engine Fuse Module Fuse 3 ^ Engine Fuse Module Fuse 5 ^ Sub-Woofer Power Power Distribution Fuse 7 - Main Light Switch, Park Lamp Relay Fuse 7 - protects the following circuits: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2198 ^ Main Light Switch ^ Park Lamp Relay Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2199 Power Distribution Fuse 8 - Main Light Switch, Headlamp Relay, Multi-function Sw Fuse 8 - protects the following circuits: ^ Main Light Switch ^ Headlamp Relay ^ Multi-function Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2200 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2201 Power Distribution Fuse 9 - DRL Module, Fog Lamp Relay Fuse 9 - protects the following circuits: ^ Daytime Running Lamps Module ^ Fog Lamp Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2202 Power Distribution Fuse 10 - Instrument Panel Aux. Power Socket Fuse 10 - protects the following circuits: ^ Instrument Panel Auxiliary Power Socket Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2203 Power Distribution Fuse 11 - Console Aux. Power Socket Fuse 11 - protects the following circuits: ^ Console Auxiliary Power Socket Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2204 Power Distribution Fuse 12 - Rear Wiper Up And Down Motor Relays Fuse 12 - protects the following circuits: ^ Rear Wiper Up Motor Relay ^ Rear Wiper Down Motor Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2205 Power Distribution Fuse 13 - Auxiliary A/C Relay Fuse 13 - protects the following circuits: ^ Auxiliary A/C Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2206 Power Distribution Fuse 14 - 4 Wheel Anti-Lock Brake System Module Fuse 14 - protects the following circuits: ^ 4 Wheel Anti-Lock Brake System Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2207 Power Distribution Fuse 15 - Air Suspension Solid State Compressor Relay Fuse 15 - protects the following circuits: ^ Air Suspension Solid State Compressor Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2208 Power Distribution Fuse 16 - Trailer Tow Bttry Charge Relay, Eng Fuse Module Fuse2 Fuse 16 - protects the following circuits: ^ Trailer Tow Battery Charge Relay ^ Engine Fuse Module Fuse 2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2209 Power Distribution Fuse 17 - Shift-On-The-Fly Relay, Tranfer Case Shift Relay Fuse 17 - protects the following circuits: ^ Shift On The Fly Relay ^ Transfer Case Shift Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2210 Power Distribution Fuse 18 - Power Seat Control Switch Fuse 18 - protects the following circuits: ^ Power Seat Control Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2211 Power Distribution Fuse 19 - Fuel Pump Relay Fuse 19 - protects the following circuits: ^ Fuel Pump Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2212 Power Distribution Fuse 20 - Ignition Switch Fuse 20 - protects the following circuits: ^ Ignition Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2213 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2214 Power Distribution Fuse 21 - Ignition Switch Fuse 21 - protects the following circuits: ^ Ignition Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2215 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2216 Power Distribution Fuse 22 - Junction Box Fuse/Relay Panel Battery Feed Fuse 22 - protects the following circuits: ^ Junction Box Fuse/Relay Panel Battery Feed Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2217 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2218 Power Distribution Fuse 23 - Instrument Panel Blower Relay Fuse 23 - protects the following circuits: ^ Instrument Panel Blower Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2219 Power Distribution Fuse 24 - PCM Power Relay, Engine Fuse Module Fuse 1 Fuse 24 - protects the following circuits: ^ PCM Power Relay ^ Engine Fuse Module Fuse 1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2220 Power Distribution Fuse 25 - Junction Box Fuse/Relay Panel, Accessory Delay Relay Fuse 25 - protects the following circuits: ^ Junction Box Fuse/Relay Panel ^ Accessory Delay Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2221 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2222 Power Distribution Fuse 27 - Junction Box Fuse/Relay Panel, Heated Grid Relay Fuse 27 - protects the following circuits: ^ Junction Box Fuse/Relay Panel ^ Heated Grid Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2223 Power Distribution Fuse 28 - Trailer Electronic Brake Controller Fuse 28 - protects the following circuits: ^ Trailer Electronic Brake Controller Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2224 Power Distribution Fuse 29 - Flip Window Relay, Hybrid Cooling Fan Relay Fuse 29 - protects the following circuits: ^ Flip Window Relay ^ Hybrid Cooling Fan Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2225 Power Distribution Circuit-to-Fuse Cross Reference 4 Wheel Air Suspension Module ......................................................................................................... ........................................................................ Fuse 6 4 Wheel Air Suspension ................................. ........................................................................................................................................................... Fuse 20 4 Wheel Anti-Lock Brake System Module ............................................................................. ................................................................................... Fuse 25 4 Wheel Anti-Lock Brake System Relay ................................................................................................................................................... ................ Fuse 25 4X4 Center Axle Disconnect Solenoid .................................................................. .................................................................................................... Fuse 23 Air Bag Diagnostic Monitor .............................................................................................................................................................. ............... Fuse 19 & 22 Autolamp Module .......................................................................................... ..................................................................................................... Fuse 4 & 29 Auxiliary A/C Control Module ................................................................................................................................................. ................................ Fuse 23 Auxiliary A/C Mode Actuator ................................................................. .................................................................................................................. Fuse 23 Auxiliary A/C Relay ................................................................................................................................................... ................................................. Fuse 7 Battery Saver Relay ............................................................... .................................................................................................................................... Fuse 14 Blend Door Actuator ...................................................................................................................................... ............................................................. Fuse 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2226 Brake On/Off Switch ............................................................................................................................ ..................................................................... Fuse 13 Brake Pressure Switch .................................... ........................................................................................................................................................... Fuse 13 Cigar Lighter .......................................................................................................................... ...................................................................................... Fuse 3 Coil On Plugs .................................... .............................................................................................................................................................. ........... Fuse 30 Compass Sensor ....................................................................................................... .................................................................................................... Fuse 6 Console Blower Motor ........ .............................................................................................................................................................. .......................... Fuse 7 Data Link Connector ..................................................................................... ............................................................................................................. Fuse 12 Daytime Running Lamps Module ..................................................................................................................................... ............................. Fuse 5,16 & 26 Digital Transmission Range Sensor ............................................. ....................................................................................................................... Fuse 5 & 21 Electronic Variable Orifice Module ....................................................................................................................... ..................................................... Fuse 5 Flasher Relay .................................................................... ........................................................................................................................................... Fuse 1 Fog Lamp Relay .................................................................................................................................. ....................................................................... Fuse 27 Function Selector Switch ............................... ................................................................................................................................................... Fuse 23 & 24 Generic Electronic Module ..................................................................................................... .................................................................. Fuse 6,18,15 & 20 Headlamp Relay ................................. .............................................................................................................................................................. ............ Fuse 4 Heated Backlight Switch ............................................................................................. ............................................................................................... Fuse 17 Heated Grid Relay ................. .............................................................................................................................................................. ........................ Fuse 6 Heater-A/C Control Assembly ........................................................................ ............................................................................................................. Fuse 5 High Beam Headlamps .......................................................................................................................................... .................................................... Fuse 16 Ignition Coil ....................................................................... ........................................................................................................................................ Fuse 30 Instrument Cluster ............................................................................................................................... ........................................................... Fuse 2,19 & 29 Instrument Cluster (Without Daytime Running Lamps) ............................................................................................................................................ Fuse 16 Instrument Illumination .......................................................................................................... .................................................................................... Fuse 18 Interior Lamp Relay .......................... .............................................................................................................................................................. ........... Fuse 14 Junction Box Fuse/Relay Panel ................................................................................. ................................................................................................ Fuse 21 Junction Box Fuse Relay Panel Fuse 20 ..................................................................................................................................... ............................... Fuse 21 Left Headlamp ....................................................................................... .................................................................................................................... Fuse 28 Left Power/Heated Signal Mirror ................................................................................................................ .............................................................. Fuse 17 Main Light Switch ................................................... ...................................................................................................................................... Fuse 8,18 & 27 Overhead Trip Computer Module ................................................................................................... ...................................................................... Fuse 2 & 6 PCM Power Diode ...................................... .............................................................................................................................................................. . Fuse 30 Park Lamp Relay ................................................................................................................. ........................................................................................ Fuse 4 Passive Anti-Theft System Module . .............................................................................................................................................................. ............ Fuse 15 Power Mirror Switch ................................................................................................. .................................................................................................. Fuse 4 Radio Noise Capacitor .......... .............................................................................................................................................................. ....................... Fuse 30 Radio ............................................................................................................. .............................................................................................................. Fuse 8 Rear Integrated Control Panel ....................................................................................................................................... ............................................. Fuse 23 Rear Wiper Pump Relay .......................................................... .................................................................................................................................. Fuse 11 Recirculation Vacuum Solenoid ........................................................................................................... ..................................................................... Fuse 23 Remote Anti-Theft Personality Module ............ .................................................................................................................................................... Fuse 4 & 8 Right Headlamp ......................................................................................................................... ................................................................................ Fuse 26 Right Power/Heated Signal Mirror ........ .............................................................................................................................................................. ...... Fuse 17 Shift Lock Actuator ......................................................................................................... ............................................................................................ Fuse 6 Speed Control Servo/Amplifier Assembly ............................................................................................................................................. ...................... Fuse 5 Steering Wheel Rotation Sensor ...................................................................... ............................................................................................................ Fuse 6 Trailer Tow Battery Charge Relay ....................................................................................................................................... ...................................... Fuse 23 Transmission Control Switch .......................................................... ........................................................................................................................... Fuse 29 Washer Pump Relay ......................................................................................................................................... .......................................................... Fuse 11 Windshield Wiper Motor ............................................. .............................................................................................................................................. Fuse 11 Wiper High/Low Relay ......................................................................................................................... ..................................................................... Fuse 11 Wiper Run/Park Relay ..................................... .......................................................................................................................................................... Fuse 11 Fuse 1 - Flasher Relay Fuse 1 - protects the following circuits: ^ Flasher Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2227 Power Distribution Fuse 2 - Instrument Cluster, OH Trip Computer Fuse 2 - protects the following circuits: ^ Instrument Cluster ^ Overhead Trip Computer Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2228 Power Distribution Fuse 3 - Cigar Lighter Fuse 3 - protects the following circuits: ^ Cigar Lighter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2229 Power Distribution Fuse 4 - Park & Hdlp Relays, Autolamp & RAP Mdl, Pwr Mirror Sw. Fuse 4 - protects the following circuits: ^ Park Lamp Relay ^ Headlamp Relay ^ Autolamp Module ^ Remote Anti-Theft Personality Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2230 ^ Power Mirror Switch Power Distribution Fuse 5 - TRS, DRL Mdl, Spd Ctrl Servo/Amp Assy, HVAC Ctrl Assy Fuse 5 - protects the following circuits: ^ Digital Transmission Range Sensor ^ Daytime Running Lamps Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2231 ^ Speed Control Servo/Amplifier Assembly ^ Heater-A/C Control Assembly ^ Blend Door Actuator ^ Electronic Variable Orifice Module Power Distribution Fuse 6 - Shift Lock, GEM, Air Susp. Mdl, OH Trip Cmptr, Compass Fuse 6 - protects the following circuits: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2232 ^ Shift Lock Actuator ^ Generic Electronic Module ^ 4 Wheel Air Suspension Module ^ Compass Sensor ^ Steering Wheel Rotation Sensor ^ Heated Grid Relay ^ Overhead Trip Computer Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2233 Power Distribution Power Distribution Fuse 7 - Aux. A/C Relay, Blower Motor Fuse 7 - protects the following circuits: ^ Auxiliary A/C Relay ^ Console Blower Motor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2234 Power Distribution Fuse 8 - Radio, Main Light Switch, RAP Module Fuse 8 - protects the following circuits: ^ Radio ^ Main Light Switch ^ Remote Anti-Theft Personality Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2235 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2236 Power Distribution Fuse 11 - Washer Pump, Wiper Run/Park Hi/Lo Relays, Wiper Motor Fuse 11 - protects the following circuits: ^ Washer Pump Relay ^ Wiper Run/Park Relay ^ Wiper High/Low Relay ^ Windshield Wiper Motor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2237 ^ Rear Wiper Pump Relay Power Distribution Fuse 12 - Data Link Connector Fuse 12 - protects the following circuits: ^ Data Link Connector Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2238 Power Distribution Fuse 13 - Brake Pedal Position and Brake Pressure Switches Fuse 13 - protects the following circuits: ^ Brake On/Off Switch ^ Brake Pressure Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2239 Power Distribution Fuse 14 - Battery Saver and Interior Lamp Relays Fuse 14 - protects the following circuits: ^ Battery Saver Relay ^ Interior Lamp Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2240 Power Distribution Fuse 15 - GEM and RAP Modules Fuse 15 - protects the following circuits: ^ Generic Electronic Module ^ Passive Anti-Theft System Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2241 Power Distribution Fuse 16 - Inst. Cluster, DRL Module, High Beam Headlamps Fuse 16 - protects the following circuits: ^ Instrument Cluster (Without Daytime Running Lamps) ^ Daytime Running Lamps Module ^ High Beam Headlamps Power Source Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2242 Power is Supplied Through Multi-Function Switch Power Distribution Fuse 17 - Htd Backlight Sw, Left & Right Pwr/Htd Signal Mirrors Fuse 17 - protects the following circuits: ^ Heated Backlight Switch ^ Left Power/Heated Signal Mirror Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2243 ^ Right Power/Heated Signal Mirror Power Distribution Fuse 18 - Main Light Sw, GEM, Instr. Illumination Fuse 18 - protects the following circuits: ^ Main Light Switch ^ Generic Electronic Module ^ Instrument Illumination Power Source Power is Supplied Through Main Light Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2244 Power Distribution Fuse 19 - Instrument Cluster, Air Bag Diagnostic Monitor Fuse 19 - protects the following circuits: ^ Instrument Cluster ^ Air Bag Diagnostic Monitor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2245 Power Distribution Fuse 20 - 4 Wheel Air Suspension, GEM Fuse 20 - protects the following circuits: ^ 4 Wheel Air Suspension ^ Generic Electronic Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2246 Power Distribution Fuse 21 - Digital Trans. Range Snsr, JB Fuse/Relay Pnl Fuse 20 Fuse 21 - protects the following circuits: ^ Digital Transmission Range Sensor ^ Junction Box Fuse/Relay Panel Fuse 20 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2247 Power Distribution Fuse 22 - Air Bag Diagnostic Monitor Fuse 22 - protects the following circuits: ^ Air Bag Diagnostic Monitor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2248 Power Distribution Fuse 23 - Tow Btty Chg Relay, 4X4 Ctr Axle Disc, Func Selector Fuse 23 - protects the following circuits: ^ Trailer Tow Battery Charge Relay ^ 4X4 Center Axle Disconnect Solenoid Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2249 ^ Function Selector Switch ^ Rear Integrated Control Panel ^ Recirculation Vacuum Solenoid ^ Auxiliary A/C Mode Actuator ^ Auxiliary A/C Control Module Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2250 Fuse 24 - Function Selector Switch Fuse 24 - protects the following circuits: ^ Function Selector Switch Power Distribution Fuse 25 - 4WABS Module and 4WABS Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2251 Fuse 25 - protects the following circuits: ^ 4 Wheel Anti-Lock Brake System Module ^ 4 Wheel Anti-Lock Brake System Relay Power Distribution Fuse 26 - DRL Module and Right Headlamp Fuse 26 - protects the following circuits: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2252 ^ Daytime Running Lamps Module ^ Right Headlamp Power Source Power is Supplied Through Multi-Function Switch Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2253 Fuse 27 - Main Light Switch and Fog Lamp Relay Fuse 27 - protects the following circuits: ^ Main Light Switch ^ Fog Lamp Relay Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2254 Fuse 28 - Left Headlamp Fuse 28 - protects the following circuits: ^ Left Headlamp Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2255 Fuse 29 - Autolamp Module, Instrument Cluster, Trans Ctrl Sw Fuse 29 - protects the following circuits: ^ Autolamp Module ^ Instrument Cluster ^ Transmission Control Switch Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2256 Fuse 30 - Radio Noise Cap., Ignition Coil, PCM Pwr Diode... Fuse 30 - protects the following circuits: ^ Radio Noise Capacitor ^ Ignition Coil ^ PCM Power Diode ^ Coil On Plugs Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2257 Power Distribution Circuit-to-Fuse Cross Reference Compact Disc Changer ....................................................................................................................... ......................................................................... Fuse 3 Powertrain Control Module ............................ ............................................................................................................................................................. Fuse 1 Premium Sound Amplifier ........................................................................................................ ................................................................................... Fuse 5 Radio ................................................... .............................................................................................................................................................. .......... Fuse 3 Rear Integrated Control Panel ...................................................................................... ................................................................................................ Fuse 3 Sub-Woofer Power ................. .............................................................................................................................................................. ....................... Fuse 5 Trailer Tow Left Turn Relay ............................................................................. .......................................................................................................... Fuse 2 Trailer Tow Right Turn Relay ................................................................................................................................................... .................................. Fuse 2 Fuse 1 - Powertrain Control Module Fuse 1 - protects the following circuits: ^ Powertrain Control Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2258 Power Distribution Fuse 2 - Trailer Turn Signal Relays Fuse 2 - protects the following circuits: ^ Trailer Tow Left Turn Relay ^ Trailer Tow Right Turn Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2259 Power Distribution Fuse 3 - Radio, Rear Int. Control Panel, CD Changer Fuse 3 - protects the following circuits: ^ Radio ^ Rear Integrated Control Panel ^ Compact Disc Changer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2260 Power Distribution Fuse 5 - Subwoofer, Prem. Sound Amplifier Fuse 5 - protects the following circuits: ^ Sub-Woofer Power ^ Premium Sound Amplifier Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2261 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2262 Engine Fuse Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2263 Junction Box Fuse/Relay Panel (Part 1 Of 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2264 Junction Box Fuse/Relay Panel (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2265 Power Distribution Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2266 Primary Battery Fuses Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Blower/Flasher Relay Block Relay Box: Locations Blower/Flasher Relay Block Instrument Panel View The Blower/Flasher Relay Block is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Blower/Flasher Relay Block > Page 2271 Relay Box: Locations Lock Relays Body View The Lock Relays are located behind right side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Blower/Flasher Relay Block > Page 2272 Relay Box: Locations Regular Production Option Relay Block Instrument Panel View The Regular Production Option Relay Block is located in dash, above passenger air bag. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block Power/Flasher Relay Block Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 2275 Lock Relays Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 2276 Power Distribution Relay Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 2277 RPO Relay Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection Malfunction Indicator Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair NOTE : The RESET procedure is found ONLY in the Owners Manual. For most Ford vehicles, the RESET procedure mainly includes just pressing the RESET button for five(5) seconds but it is recommended that the Owners Manual is consulted first. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair Front Jacking Points 1. The jacking point is a raised boss located on the front suspension lower arm. WARNING: The electrical power to the air suspension system must be shut down prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning OFF the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. WARNING: DO NOT run the engine when jacking the vehicle. The wheels contacting the ground could cause the vehicle to move. WARNING: Support the vehicle prior to performing any procedure requiring the vehicle to be lifted off of the ground. WARNING: Make sure jack and jack stands are properly located to prevent the vehicle from falling. WARNING: Wheel chocks should be used to prevent the vehicle from rolling and falling off the jack. Rear Jacking Points 1. The jacking point is a bracket welded to the frame. WARNING: The electrical power to the air suspension system must be shut down prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning OFF the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. WARNING: DO NOT run the engine when jacking the vehicle. The wheels contacting the ground could cause the vehicle to move. WARNING: Support the vehicle prior to performing any procedure requiring the vehicle to be lifted off of the ground. WARNING: Make sure jack and jack stands are properly located to prevent the vehicle from falling. WARNING: Wheel chocks should be used to prevent the vehicle from rolling and falling off the jack. Twin Post Hoist Lifting Points Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Page 2289 1. Locate front hoist adapters and rear hoist adapters (top of frame arc) as indicated. WARNING: The electrical power to the air suspension system must be shut down prior to hoisting, jacking, or towing an air suspension vehicle. This can be accomplished by turning OFF the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. CAUTION: Damage to suspension, exhaust, and steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Drive on Hoist Lifting Points 1. Vehicle is supported by tires and suspension components. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Specifications Spare Tire: Specifications Spare Tire Carrier Bolts ....................................................................................................................... .......................................... 23-32 Nm (17-23 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Specifications > Page 2294 Spare Tire: Service and Repair REMOVAL 1. Lower the spare tire. (1) Insert the drive end of the jack handle through the opening left of the license plate. (2) Turn the jack handle until slack is present in the cable. 2. Remove the spare tire. (1) Slide the retainer through the center of the spare tire assembly. (2) Remove the spare tire assembly. WARNING: THEE ELECTRICAL POWER TO THEE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 3. Raise and support the vehicle. 4. Remove the spare tire carrier. (1) Remove the two bolts. (2) Turn the spare tire carrier to disengage the spare tire carrier from the tabs and remove the spare tire carrier. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Specifications > Page 2295 INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2300 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2301 Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2302 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2303 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2304 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2305 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2306 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2307 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2308 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2309 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2310 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2311 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2312 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2313 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2314 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2315 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2316 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2317 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2318 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2319 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2320 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2321 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2322 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2323 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2324 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2325 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2326 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2327 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2328 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2329 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2330 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2331 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2332 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2333 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2334 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2335 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2336 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2337 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2338 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2339 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2340 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2341 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2342 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2343 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2344 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2345 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2346 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2347 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2348 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2349 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2350 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2351 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2352 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2353 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2354 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2355 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2356 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2357 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2358 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2359 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2360 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2361 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2362 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2363 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2364 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2365 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2366 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2367 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2368 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2369 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2370 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2371 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2372 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2373 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2374 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2375 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2376 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2377 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2378 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2379 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2380 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2381 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2382 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2383 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2384 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2385 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2386 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2387 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2388 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2389 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2390 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2391 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2392 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2393 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2394 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2395 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2396 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 2397 Wheels: Specifications GENERAL Cast Aluminum .................................................................................................................................... .................................................................. 17x7.5J Steel .................................................................... ...................................................................................................................................................... 16x7J Styled Aluminum ....................................................................................................................... ............................................................................... 16x7J Styled Argent Steel ................................... .............................................................................................................................................................. .. 16x7J Max Balance Weight (Total of Inner & Outer Flanges) ................................................................................................................................. 170 g (6 oz) Wheel Offset ........................................................................................................................................ ................................................................... 14 mm Wheel Rim Runout (Radial or Lateral) ................................................................................................................................................ 1.12 mm (0.044 in) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Wheels: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2400 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2401 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2402 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2403 Wheels: Component Tests and General Diagnostics Runout TEST DESCRIPTION Excessive radial and lateral runout of a wheel and tire assembly can cause roughness, vibration, wheel tramp, tire wear, and steering wheel tremor. Before checking runout and to avoid false readings caused by temporary flat spots in the tires, check runout only after the vehicle has been driven far enough to warm tires. The extent of the runout is measured with Radial Runout Gauge. All measurements are made on the vehicle with the tires inflated to recommended inflation pressures and with the front wheel bearings adjusted to specifications. TIRE RUNOUT Use Radial Runout Gauge to measure (A) radial runout of the tire at the center and outside ribs of the tread face. Mark the high points of radial runout for future reference. Radial runout should not exceed specifications. WHEEL RUNOUT Measure (B) radial and (C) lateral wheel runout at the positions shown in the illustration. Runout should not exceed specifications. Wheel Centering 0-Ring Seal The front hub and rear axle wheel pilots are fitted with rubber O-rings which help center the wheels. Remove the O-ring and clean the machined groove and clean and lubricate the O-ring if required. Replace the O-ring if damaged. O-rings should be pulled on (not pushed) so that the yellow paint identification stripe is visible after installation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Testing and Inspection > Page 2404 Wheels: Service and Repair REMOVAL 1. Loosen the lug nuts. (1) Remove the center cap. (2) With the weight of the vehicle on the wheels, loosen the lug nuts. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and wheel bearings. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MA Y RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Raise and support the vehicle. 3. Remove the wheel and tire assembly. (1) Remove the lug nuts. (2) Remove the wheel and tire assembly. INSTALLATION 1. Clean the wheel hub mounting surface. WARNING: WHEN A WHEEL IS INSTALLED, ALWAYS REMOVE ANY CORROSION, DIRT OR FOREIGN MATERIAL PRESENT ON THE MOUNTING SURFACES OF THE WHEEL OR THE SURFACE OF THE WHEEL HUB, BRAKE DRUM OR BRAKE ROTOR THAT CONTACTS THE WHEEL. INSTALLING WHEELS WITHOUT PROPER METAL TO METAL CONTACT AT THE WHEEL MOUNTING SURFACES CAN CAUSE THE LUG NUTS TO LOOSEN AND THE WHEEL TO COME OFF WHILE THE VEHICLE IS IN MOTION, CAUSING LOSS OF CONTROL. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Testing and Inspection > Page 2405 2. Install the tire and wheel assembly. (1) Position the tire and wheel assembly (2) Install the lug nuts and lower the vehicle. (3) Tighten in sequence the lug nuts. (4) Install the wheel cover. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2410 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2411 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2412 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2413 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2414 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2415 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2416 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2417 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2418 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2419 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2420 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2421 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2422 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2423 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2424 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2425 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2426 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2427 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2428 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2429 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2430 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2431 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2432 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2433 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2434 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2435 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2436 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2437 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2438 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2439 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2440 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2441 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2442 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2443 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2444 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2445 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2446 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2447 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2448 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2449 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2450 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2451 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2452 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2453 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2454 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2455 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2456 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2457 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2458 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2459 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2460 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2461 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2462 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2463 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2464 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2465 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2466 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2467 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2468 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2469 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2470 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2471 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2472 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2473 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2474 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2475 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2476 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2477 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2478 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2479 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2480 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2481 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2482 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2483 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2484 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2485 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2486 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2487 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2488 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2489 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2490 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2491 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2492 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2493 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2494 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2495 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2496 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2497 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2498 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2499 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2500 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2501 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2502 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2503 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2504 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Page 2505 Wheel Bearing: Specifications ^ Lubricate the new rear axle bearing. Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. ^ Lubricate the lip of the new axle shaft oil seal. Use Premium Long-Life Grease XG-1-C or XG-1-K or equivalent meeting Ford specification ESA-M1C75-B. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications TORQUE SPECIFICATIONS Front Axle Hub Nut ........................................................................................................................................................... 255-345 Nm (188-254 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls: > NHTSA98V095000 > May > 98 > Recall 98V095000: Lug Nut Replacement Wheel Fastener: Recalls Recall 98V095000: Lug Nut Replacement Year: 1997, 1998 Make: LINCOLN TRUCK, FORD TRUCK Model: NAVIGATOR, EXPEDITION, F150, F250 Year of Recall: '98 Type of Report: Vehicle Potential Number of Units Affected: 1520000 Summary: Vehicle Description: Multi-purpose vehicles and light duty pickup trucks. The lug nuts on these vehicles may not create sufficient clamp load allowing wheel movement in relation to the hub/rotor mounting surface. This can result in the loosening of lug nuts, stud fatigue failure, and the potential for a wheel separation from the vehicle, increasing the risk of a vehicle crash. Dealers will inspect the wheel studs and replace the wheel lug nuts. Owner notification is expected to begin July 20, 1998. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > NHTSA98V095000 > May > 98 > Recall 98V095000: Lug Nut Replacement Wheel Fastener: All Technical Service Bulletins Recall 98V095000: Lug Nut Replacement Year: 1997, 1998 Make: LINCOLN TRUCK, FORD TRUCK Model: NAVIGATOR, EXPEDITION, F150, F250 Year of Recall: '98 Type of Report: Vehicle Potential Number of Units Affected: 1520000 Summary: Vehicle Description: Multi-purpose vehicles and light duty pickup trucks. The lug nuts on these vehicles may not create sufficient clamp load allowing wheel movement in relation to the hub/rotor mounting surface. This can result in the loosening of lug nuts, stud fatigue failure, and the potential for a wheel separation from the vehicle, increasing the risk of a vehicle crash. Dealers will inspect the wheel studs and replace the wheel lug nuts. Owner notification is expected to begin July 20, 1998. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure Wheel Fastener: All Technical Service Bulletins Lug Nuts - Proper Installation/Torqueing Procedure Article No. 98-5A-4 ^ BRAKES - PREVENTING BRAKE VIBRATION - SERVICE TIP ^ WHEELS - PROPER LUG TORQUE PROCEDURES - SERVICE TIP FORD: 1972-97 THUNDERBIRD 1976-86 LTD 1976-97 MUSTANG 1981-97 CROWN VICTORIA 1982-88 EXP 1982-98 ESCORT 1984-94 TEMPO 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1979-83 MONARCH, ZEPHYR 1979-97 COUGAR 1980-83 MARK VI 1980-98 CONTINENTAL, TOWN CAR 1981-86 LYNX 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-97 SABLE 1987-89 TRACER 1987-97 GRAND MARQUIS 1991-94 CAPRI 1991-97 TRACER 1993-98 MARK VIII 1995-98 MYSTIQUE LIGHT TRUCK: 1979-96 BRONCO 1979-97 ECONOLINE, F-150-350 SERIES 1984-90 BRONCO II 1984-97 RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-98 WINDSTAR 1997 EXPEDITION 1998 NAVIGATOR ISSUE: The use of air impact tools to tighten wheel lug nuts can lead to overtightened and/or unevenly tightened wheel lug nuts. Air impact tools typically used for wheel lug nut removal and installation can generate up to 475 N.m (350 lb-ft) of torque. Overtightened and/or unevenly torqued wheel lug nuts may cause: ^ Brake vibration ^ Distortion of the wheel hub ^ Distortion of the brake rotor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure > Page 2527 ^ Brake rotor runout ^ Damage to the wheel ^ Damage to the wheel nuts and studs ACTION: All wheel lug nuts should only be tightened to specification using a torque wrench or by using the Rotunda ACCUTORO 164-R0314 or equivalent on a 1/2" drive air impact tool. The "ACCUTORO" lug nut sockets limit the torque of the air impact tool, preventing overtightening or uneven tightening of the wheel lug nuts. The torque limiting devices (regulators) on air impact tools will not reduce the output torque enough to prevent overtightening of the wheel lug nuts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure > Page 2528 NOTE: REFER TO THE APPROPRIATE SERVICE MANUAL OR THE CHART IN FIGURE 1 FOR THE CORRECT WHEEL LUG NUT TORQUE SPECIFICATION. THE CHART IN FIGURE 1 ALSO PROVIDES THE CORRECT "ACCUTORO" LUG NUT SOCKET TO USE. The "ACCUTORO" socket is intended for lug nut installation, not removal. When using the "ACCUTORO" socket, the output torque of the air impact tool must be set to 217-339 N.m (160-250 lb-ft), usually this will be the lowest setting on the air impact tool. The "ACCUTORO" lug nut sockets are available through Rotunda Equipment. The four-piece set (164-R0314) fits most Ford Motor Company cars and light trucks. The tool set consists of four (4) lug nut sockets and a storage case. The set can be ordered by calling Rotunda Equipment at 1-800-ROT-UNDA (768-8632). CAUTION: AIR IMPACT TOOLS SHOULD NOT BE USED TO TIGHTEN WHEEL LUG NUTS UNLESS THE "ACCUTORO" LUG NUT SOCKET OF THE CORRECT SPECIFICATION IS USED. NOTE: DO NOT USE AIR IMPACT TOOLS ON LOCKING WHEEL LUG NUTS. THEY ARE TO BE HAND-TORQUED ONLY. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-17-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 303000, 306000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure Wheel Fastener: All Technical Service Bulletins Lug Nuts - Proper Installation/Torqueing Procedure Article No. 98-5A-4 ^ BRAKES - PREVENTING BRAKE VIBRATION - SERVICE TIP ^ WHEELS - PROPER LUG TORQUE PROCEDURES - SERVICE TIP FORD: 1972-97 THUNDERBIRD 1976-86 LTD 1976-97 MUSTANG 1981-97 CROWN VICTORIA 1982-88 EXP 1982-98 ESCORT 1984-94 TEMPO 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1979-83 MONARCH, ZEPHYR 1979-97 COUGAR 1980-83 MARK VI 1980-98 CONTINENTAL, TOWN CAR 1981-86 LYNX 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-97 SABLE 1987-89 TRACER 1987-97 GRAND MARQUIS 1991-94 CAPRI 1991-97 TRACER 1993-98 MARK VIII 1995-98 MYSTIQUE LIGHT TRUCK: 1979-96 BRONCO 1979-97 ECONOLINE, F-150-350 SERIES 1984-90 BRONCO II 1984-97 RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-98 WINDSTAR 1997 EXPEDITION 1998 NAVIGATOR ISSUE: The use of air impact tools to tighten wheel lug nuts can lead to overtightened and/or unevenly tightened wheel lug nuts. Air impact tools typically used for wheel lug nut removal and installation can generate up to 475 N.m (350 lb-ft) of torque. Overtightened and/or unevenly torqued wheel lug nuts may cause: ^ Brake vibration ^ Distortion of the wheel hub ^ Distortion of the brake rotor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure > Page 2534 ^ Brake rotor runout ^ Damage to the wheel ^ Damage to the wheel nuts and studs ACTION: All wheel lug nuts should only be tightened to specification using a torque wrench or by using the Rotunda ACCUTORO 164-R0314 or equivalent on a 1/2" drive air impact tool. The "ACCUTORO" lug nut sockets limit the torque of the air impact tool, preventing overtightening or uneven tightening of the wheel lug nuts. The torque limiting devices (regulators) on air impact tools will not reduce the output torque enough to prevent overtightening of the wheel lug nuts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure > Page 2535 NOTE: REFER TO THE APPROPRIATE SERVICE MANUAL OR THE CHART IN FIGURE 1 FOR THE CORRECT WHEEL LUG NUT TORQUE SPECIFICATION. THE CHART IN FIGURE 1 ALSO PROVIDES THE CORRECT "ACCUTORO" LUG NUT SOCKET TO USE. The "ACCUTORO" socket is intended for lug nut installation, not removal. When using the "ACCUTORO" socket, the output torque of the air impact tool must be set to 217-339 N.m (160-250 lb-ft), usually this will be the lowest setting on the air impact tool. The "ACCUTORO" lug nut sockets are available through Rotunda Equipment. The four-piece set (164-R0314) fits most Ford Motor Company cars and light trucks. The tool set consists of four (4) lug nut sockets and a storage case. The set can be ordered by calling Rotunda Equipment at 1-800-ROT-UNDA (768-8632). CAUTION: AIR IMPACT TOOLS SHOULD NOT BE USED TO TIGHTEN WHEEL LUG NUTS UNLESS THE "ACCUTORO" LUG NUT SOCKET OF THE CORRECT SPECIFICATION IS USED. NOTE: DO NOT USE AIR IMPACT TOOLS ON LOCKING WHEEL LUG NUTS. THEY ARE TO BE HAND-TORQUED ONLY. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-17-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 303000, 306000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Fastener Wheel Fastener: Specifications Wheel Fastener TORQUE Lug Nuts: 113-153 Nm (83-112 ft. lbs.) GENERAL Lug Nuts (metric): M12 x 1.75 - 19 mm hex Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Fastener > Page 2538 Wheel Fastener: Specifications Wheel Stud Wheel Stud (metric) ............................................................................................................................. ........................................... M12 x 1.75 - 19 mm hex Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 2539 Wheel Fastener: Service and Repair REMOVAL 1. Remove the wheel hub. 2. Remove the damaged lug bolts. CAUTION: Do not press on bearing when removing or installing lug bolts. INSTALLATION NOTE: The wheel bearing and hub are replaced as an assembly. 1. Install the new lug bolts. CAUTION: Do not press on bearing when removing or installing lug bolts. 2. Install the wheel hub. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair Front Jacking Points 1. The jacking point is a raised boss located on the front suspension lower arm. WARNING: The electrical power to the air suspension system must be shut down prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning OFF the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. WARNING: DO NOT run the engine when jacking the vehicle. The wheels contacting the ground could cause the vehicle to move. WARNING: Support the vehicle prior to performing any procedure requiring the vehicle to be lifted off of the ground. WARNING: Make sure jack and jack stands are properly located to prevent the vehicle from falling. WARNING: Wheel chocks should be used to prevent the vehicle from rolling and falling off the jack. Rear Jacking Points 1. The jacking point is a bracket welded to the frame. WARNING: The electrical power to the air suspension system must be shut down prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning OFF the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. WARNING: DO NOT run the engine when jacking the vehicle. The wheels contacting the ground could cause the vehicle to move. WARNING: Support the vehicle prior to performing any procedure requiring the vehicle to be lifted off of the ground. WARNING: Make sure jack and jack stands are properly located to prevent the vehicle from falling. WARNING: Wheel chocks should be used to prevent the vehicle from rolling and falling off the jack. Twin Post Hoist Lifting Points Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair > Page 2543 1. Locate front hoist adapters and rear hoist adapters (top of frame arc) as indicated. WARNING: The electrical power to the air suspension system must be shut down prior to hoisting, jacking, or towing an air suspension vehicle. This can be accomplished by turning OFF the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. CAUTION: Damage to suspension, exhaust, and steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Drive on Hoist Lifting Points 1. Vehicle is supported by tires and suspension components. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart above. If one or more cylinders reads low, squirt approximately one tablespoon of clean engine oil meeting Ford specification ESE-M2C153-E on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > System Diagnosis > Gauge Check Compression Check: Testing and Inspection Gauge Check 1. Make sure the oil in the crankcase is of the correct viscosity and at the proper level and that the battery is properly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as Compression Tester in No.1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, use the auxiliary starter switch to crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > System Diagnosis > Gauge Check > Page 2551 Compression Check: Testing and Inspection Interpreting Compression Readings 1. If compression improves considerably, the piston rings are faulty. 2. If compression does not improve, the valves are sticking or seating improperly. 3. If two adjacent cylinders indicate low compression pressures and squirting oil on the piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil and/or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75 percent of the highest reading. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > System Diagnosis > Gauge Check > Page 2552 Compression Check: Testing and Inspection Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart above. If one or more cylinders reads low, squirt approximately one tablespoon of clean engine oil meeting Ford specification ESE-M2C153-E on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > System Diagnosis > Gauge Check > Page 2553 Compression Check: Testing and Inspection Cylinder Leakage Test When a cylinder produces a low reading, the use of Engine Cylinder Leak Detection/Air Pressurization Kit will be helpful in pinpointing the exact cause. The leakage detector is inserted in the spark plug hole, the piston is brought up to dead center on the compression stroke, and compressed air is admitted. Once the combustion chamber is pressurized, a special gauge included in the kit will read the percentage of leakage. Leakage exceeding 20 percent is excessive. While the air pressure is retained in the cylinder, listen for the hiss of escaping air. A leak at the intake valve will be heard in the throttle body. A leak at the exhaust valve can be heard at the tail pipe. Leakage past the piston rings will be audible at the positive crankcase ventilation (PCV) connection. If air is passing through a blown head gasket to an adjacent cylinder, the noise will be evident at the spark plug hole of the cylinder into which the air is leaking. Cracks in the cylinder block or gasket leakage into the cooling system may be detected by a stream of bubbles in the radiator. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications Camshaft Bearing: Specifications TORQUE SPECIFICATIONS Refer to illustration for tightening sequence. Camshaft Bearing Cap Bolts: 8-12 Nm (71.4-107.1 inch lbs.) DIMENSIONS Bearing Inside Diameter (All): 27.012-26.987 mm (1.063-1.0625 inch) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications TORQUE SPECIFICATIONS Camshaft Sprocket Bolt ........................................................................................................................................................ 110-130 Nm (81-95 Ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications > Page 2561 Camshaft Gear/Sprocket: Testing and Inspection WARNING: TO AVOID THE POSSIBILITY OF PERSONAL INJURY OR DAMAGE TO THE VEHICLE, DO NOT OPERATE THE ENGINE WITH THE HOOD OPEN UNTIL THE FAN BLADE HAS FIRST BEEN EXAMINED FOR POSSIBLE CRACKS AND SEPARATION. NOTE: Specifications show the expected minimum or maximum condition. If a component fails to meet the specifications, it is necessary to replace or refinish. If the component can be refinished, wear limits are provided as an aid to making a decision. Any component that fails to meet specifications and cannot be refinished must be replaced. PROCEDURE 1. Inspect the chain and the sprockets. 2. Replace as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications DIMENSIONS End Play: Standard ...................................................................................................................................................... 0.027-0.190 mm (0.00176-0.00748 inch) Service Limit ....................................................................... .................................................................................................. 0.190 mm (0.0075 inch) Journal: Diameter (All) ................................................................................................................................................. 26.962-26.936 mm (1.061-1.060 inch) Bearing Clearance: Standard............................................................................................................................................... ...... 0.025-0.076 mm (0.00098-0.003 inch) Service Limit .................................................................... ............................................................................................. 0.076 mm (0.00239 inch) Runout ................................................................................................................................................. .................................. 0.09 mm (0.00354 inch) Lobe Lift: Allowable Lift Loss ............................................................................................................................... ................................................ 0 mm (0 inch) Intake ........................................................................... .................................................................................................... 6.58077 mm (0.25978 inch) Exhaust: Left ....................................................................................................................................................... ..................... 6.59579 mm (0.25954 inch) Right ................................................................................. ......................................................................................... 6.58551 mm (0.25327 inch) Theoretical Valve Lift @ Zero Lash: Intake ................................................................................................................................................... ...................................... 12.0 mm (0.472 inch) Exhaust ...................................................................... ................................................................................................................ 12.0 mm (0.472 inch) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Testing and Inspection > Journal Camshaft: Testing and Inspection Journal Clearance NOTE: The camshaft journals must meet specification before checking camshaft journal clearance. 1. Remove the camshaft bearing cap. 2. Lay Plastigage across the face of the camshaft bearing surface. 3. Position the camshaft bearing cap and install the camshaft bearing cap bolts in the sequence indicated. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Testing and Inspection > Journal > Page 2567 4. Use Plastigage to verify the camshaft journal clearance. ^ If it is out of specification, replace as necessary. Diameter 1. Measure each camshaft journal diameter in two directions. ^ If it is out of specification, replace as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Testing and Inspection > Journal > Page 2568 Camshaft: Testing and Inspection Lobe Lobe Lift Check the lift of each camshaft lobe in consecutive order and make a note of the readings. 1. Remove the valve covers. 2. Remove the spark plugs. 3. Install Dial Indicator with Bracketry so that the rounded tip of the indicator is on top of the camshaft lobe and on the same plane as the Hydraulic Lash Adjuster (HLA). 4. Rotate the crankshaft until the base circle of the camshaft lobe is reached. 5. Zero the Dial Indicator with Bracketry. Continue to rotate the crankshaft until the (A) high-lift point of the camshaft lobe is in the fully-raised position (highest indicator reading). 6. To check the accuracy of the original indicator reading, continue to rotate the crankshaft until (B) base circle is reached. The indicator reading should be zero. If a zero reading is not obtained, repeat Steps 1 through 6. 7. Compare total lift recorded on Dial Indicator with Bracketry with specifications. NOTE: If the lift on any lobe is below the specified service limits, the camshaft roller followers operating on that cam-shaft must be replaced. 8. Remove Dial Indicator with Bracketry. 9. Install the spark plugs. 10. Install the valve covers. Lobe Surface Inspect camshaft lobes for pitting or damage in the active area. Minor pitting is acceptable outside the active area. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Testing and Inspection > Journal > Page 2569 Camshaft: Testing and Inspection End Play 1. Remove the roller followers. 2. Use Dial Indicator with Bracketry to measure camshaft end play. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Testing and Inspection > Journal > Page 2570 Camshaft: Testing and Inspection Runout NOTE: Camshaft journals must be within specification before checking runout. 1. Use Dial Indicator with Bracketry to measure the camshaft runout. 2. Rotate the camshaft and subtract the lowest dial indicator reading from the highest dial indicator reading. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Testing and Inspection > Page 2571 Camshaft: Service and Repair REMOVAL 1. Remove the cam cover. 2. Remove the timing chain. CAUTION: At no time, when the timing chains are removed and the cylinder heads are installed may the crankshaft or camshaft be rotated. Severe piston and valve damage will occur. 3. Remove the camshaft roller followers. 4. Remove the timing chain camshaft gear. a. Remove the timing chain camshaft gear bolt. b. Remove the timing chain camshaft gear. 5. Remove the thirteen camshaft bearing cap bolts. 6. Remove the camshaft bearing caps. 7. Remove the camshaft from the cylinder head. INSTALLATION 1. Lubricate the camshaft journals. ^ Use engine oil meeting Ford specifications WSE-2C908-A1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Testing and Inspection > Page 2572 2. Install the camshaft onto the cylinder head. 3. Lubricate the camshaft bearing caps. ^ Use engine oil meeting Ford specifications WSE-M2908-A1. 4. Install the camshaft bearing caps and loosely install the camshaft bearing cap bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Testing and Inspection > Page 2573 5. Tighten the camshaft bearing cap bolts in the sequence shown. 6. Install the camshaft gear. a. Position the camshaft gear. b. Install the camshaft gear bolt. 7. Install the camshaft roller followers. 8. Install the timing chain. 9. Install the cam cover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > Customer Interest for Lifter / Lash Adjuster: > 97-25-8 > Dec > 97 > Engine - Rough Running/MIL ON/DTC'S Set Lifter / Lash Adjuster: Customer Interest Engine - Rough Running/MIL ON/DTC'S Set Article No. 97-25-8 12/08/97 ^ RUNS ROUGH - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC) P0300 THROUGH P0308 MAY BE STORED IN MEMORY - VEHICLES BUILT THROUGH 11/26/97 EQUIPPED WITH 4.6L OR 5.4L ENGINE ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC) P0300 THROUGH P0308 MAY BE STORED IN MEMORY - VEHICLES BUILT THROUGH 11/26/97 EQUIPPED WITH 4.6L OR 5.4L ENGINE ^ ENGINE - ROLLER FINGER FOLLOWERS DISLODGE - DURING AMBIENT TEMPERATURES LESS THAN -18 DEGREES C (0 DEGREES F) - VEHICLES BUILT THROUGH 11/26/97 EQUIPPED WITH 4.6L OR 5.4L ENGINE LIGHT TRUCK: 1997-98 ECONOLINE, EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR ISSUE: The roller finger followers may become dislodged and end up loose in the cylinder head during ambient temperatures of less than -18°C (0°F). This may result in damage to the camshaft, roller finger follower, valve, retainer, valve guide, etc. ACTION: Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Check compression of all cylinders. 2. Remove cam cover from the affected side of the engine which showed low compression readings. Look for a follower that has become dislodged and examine all components for damage (i.e., camshaft, valve, follower, etc.). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > Customer Interest for Lifter / Lash Adjuster: > 97-25-8 > Dec > 97 > Engine - Rough Running/MIL ON/DTC'S Set > Page 2582 ^ If damage is found, contact the engine plant Hotline at the numbers listed in this article. ^ If no damage is found, remove all followers from the engine (both sides) and compare to Figure 1 to determine their revision level. 3. If they are the new revision, contact the engine plant Hotline at the numbers listed in this article. It they are the old revision level, replace all followers with new level Followers (F8AZ-6564-AA). 4. Recheck compression of all cylinders to verify proper valve train operation. 5. If compression is within specifications, reinstall the cam covers and any other engine components removed. 6. If the compression is still unacceptable, contact the engine plant Hotline at the numbers listed in this article. Engine plant telephone numbers: ^ Windsor Engine - (800) 465-4680 ^ Romeo Engine - (800) 833-4503 PART NUMBER PART NAME F8AZ-6564-AA Roller Tip Follower OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 972508A Compression Test - All 1.0 Hr. Models 972508B Replace Followers - 3.8 Hrs. F-Series, Expedition (4.6L MFI, 5.4L MFI) 972508C Replace Followers - 3.8 Hrs. Navigator (5.4L MFI) 972508D Replace Followers - 5.6 Hrs. Econoline (4.6L MFI) 972508E Replace Followers - 5.4 Hrs. Econoline (5.4L MFI) DEALER CODING CONDITION BASIC PART NO. CODE 6529 33 OASIS CODES: 499000, 608000, 609000, 610000, 614000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Lifter / Lash Adjuster: > 97-25-8 > Dec > 97 > Engine - Rough Running/MIL ON/DTC'S Set Lifter / Lash Adjuster: All Technical Service Bulletins Engine - Rough Running/MIL ON/DTC'S Set Article No. 97-25-8 12/08/97 ^ RUNS ROUGH - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC) P0300 THROUGH P0308 MAY BE STORED IN MEMORY - VEHICLES BUILT THROUGH 11/26/97 EQUIPPED WITH 4.6L OR 5.4L ENGINE ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC) P0300 THROUGH P0308 MAY BE STORED IN MEMORY - VEHICLES BUILT THROUGH 11/26/97 EQUIPPED WITH 4.6L OR 5.4L ENGINE ^ ENGINE - ROLLER FINGER FOLLOWERS DISLODGE - DURING AMBIENT TEMPERATURES LESS THAN -18 DEGREES C (0 DEGREES F) - VEHICLES BUILT THROUGH 11/26/97 EQUIPPED WITH 4.6L OR 5.4L ENGINE LIGHT TRUCK: 1997-98 ECONOLINE, EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR ISSUE: The roller finger followers may become dislodged and end up loose in the cylinder head during ambient temperatures of less than -18°C (0°F). This may result in damage to the camshaft, roller finger follower, valve, retainer, valve guide, etc. ACTION: Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Check compression of all cylinders. 2. Remove cam cover from the affected side of the engine which showed low compression readings. Look for a follower that has become dislodged and examine all components for damage (i.e., camshaft, valve, follower, etc.). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Lifter / Lash Adjuster: > 97-25-8 > Dec > 97 > Engine - Rough Running/MIL ON/DTC'S Set > Page 2588 ^ If damage is found, contact the engine plant Hotline at the numbers listed in this article. ^ If no damage is found, remove all followers from the engine (both sides) and compare to Figure 1 to determine their revision level. 3. If they are the new revision, contact the engine plant Hotline at the numbers listed in this article. It they are the old revision level, replace all followers with new level Followers (F8AZ-6564-AA). 4. Recheck compression of all cylinders to verify proper valve train operation. 5. If compression is within specifications, reinstall the cam covers and any other engine components removed. 6. If the compression is still unacceptable, contact the engine plant Hotline at the numbers listed in this article. Engine plant telephone numbers: ^ Windsor Engine - (800) 465-4680 ^ Romeo Engine - (800) 833-4503 PART NUMBER PART NAME F8AZ-6564-AA Roller Tip Follower OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 972508A Compression Test - All 1.0 Hr. Models 972508B Replace Followers - 3.8 Hrs. F-Series, Expedition (4.6L MFI, 5.4L MFI) 972508C Replace Followers - 3.8 Hrs. Navigator (5.4L MFI) 972508D Replace Followers - 5.6 Hrs. Econoline (4.6L MFI) 972508E Replace Followers - 5.4 Hrs. Econoline (5.4L MFI) DEALER CODING CONDITION BASIC PART NO. CODE 6529 33 OASIS CODES: 499000, 608000, 609000, 610000, 614000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > Page 2589 Lifter / Lash Adjuster: Specifications DIMENSIONS Diameter (Std) ......................................................................................................................................................... 16.000-15.988 mm (0.63-0.629 inch) Clearance To Bore ............................................................................................................................................ 0.018-0.069 mm (0.00071-0.00272 inch) Service Limit ....................................................................... ...................................................................................................... 0.016 mm (0.00063 inch) Collapsed Lash Adjuster Gap Desired ...................................................................................................................... 0.85-0.45 mm (0.0335-0.0177 inch) LEAKDOWN Hydraulic Leakdown Rate [1] ............................................................................................................... ........................................................ 5-25 seconds [1] Time required for plunger to leak down 1.6 mm of travel with 222 N force and leak down fluid in tappet Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > Page 2590 Lifter / Lash Adjuster: Testing and Inspection Inspect the roller for flat spots or scoring. If any damage is found, inspect the camshaft lobes and hydraulic lash adjusters for damage. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Technical Service Bulletins > Page 2591 Lifter / Lash Adjuster: Service and Repair REMOVAL 1. Remove the camshaft roller followers. 2. Remove the hydraulic lash adjusters (HLA). INSTALLATION 1. Install the hydraulic lash adjuster. 2. Install the camshaft roller followers. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold Rocker Arm Assembly: Customer Interest Engine - Rough Idle/Noise When Cold Article No. 00-26-1 12/25/00 ^ ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 ^ NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 FORD: 1997-1999 F-250 LD 1997-2000 ECONOLINE, EXCURSION, EXPEDITION, F-150 1999-2000 F SUPER DUTY LINCOLN: 1998-1999 NAVIGATOR ISSUE Some vehicles equipped with a 4.6L, 5.4L, or 6.8L engine may exhibit a rough idle/miss after start-up in cold ambient temperatures (less than -12°C/10 ° F). This may be caused by a roller finger follower(s) being dislodged from the valve. This may result in damage to the camshaft, roller finger follower, valve, retainer, etc. A procedure is now available to service this condition. ACTION Inspect and replace any worn or damaged engine valve components and install new retaining clip and lash adjuster for service. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform normal engine diagnostic routines before opening valve covers. If the valve train is suspect, remove the valve covers and look for Roller Finger Follower(s) (RFF) that may have become dislodged. 1. Inspect the following parts that may have been damaged by any dislodged roller finger followers: ^ Cam lobes (chipped or grooved) ^ Valve stem tips (mushroomed, metal displaced, or bent) ^ Roller finger followers (chipped or grooved) ^ Inspect valve guide only if its corresponding RFF or valve stem tip is damaged. Replace damaged parts as necessary. 2. If follower(s) are damaged, replaced as necessary, otherwise re-use followers in same location as removed from head. 3. Remove all intake and exhaust lash adjusters from the engine and replace with service-only Lash Adjusters (YL3Z-6500-AA). Refer to the appropriate workshop Manual, Section 303-01B for service procedures and tooling necessary to compress the valve springs and remove the roller followers. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2600 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2601 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold Rocker Arm Assembly: All Technical Service Bulletins Engine - Rough Idle/Noise When Cold Article No. 00-26-1 12/25/00 ^ ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 ^ NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 FORD: 1997-1999 F-250 LD 1997-2000 ECONOLINE, EXCURSION, EXPEDITION, F-150 1999-2000 F SUPER DUTY LINCOLN: 1998-1999 NAVIGATOR ISSUE Some vehicles equipped with a 4.6L, 5.4L, or 6.8L engine may exhibit a rough idle/miss after start-up in cold ambient temperatures (less than -12°C/10 ° F). This may be caused by a roller finger follower(s) being dislodged from the valve. This may result in damage to the camshaft, roller finger follower, valve, retainer, etc. A procedure is now available to service this condition. ACTION Inspect and replace any worn or damaged engine valve components and install new retaining clip and lash adjuster for service. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform normal engine diagnostic routines before opening valve covers. If the valve train is suspect, remove the valve covers and look for Roller Finger Follower(s) (RFF) that may have become dislodged. 1. Inspect the following parts that may have been damaged by any dislodged roller finger followers: ^ Cam lobes (chipped or grooved) ^ Valve stem tips (mushroomed, metal displaced, or bent) ^ Roller finger followers (chipped or grooved) ^ Inspect valve guide only if its corresponding RFF or valve stem tip is damaged. Replace damaged parts as necessary. 2. If follower(s) are damaged, replaced as necessary, otherwise re-use followers in same location as removed from head. 3. Remove all intake and exhaust lash adjusters from the engine and replace with service-only Lash Adjusters (YL3Z-6500-AA). Refer to the appropriate workshop Manual, Section 303-01B for service procedures and tooling necessary to compress the valve springs and remove the roller followers. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2607 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2608 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Page 2609 Rocker Arm Assembly: Specifications DIMENSIONS Rocker Arm-Ratio ................................................................................................................................ .................................................................... 1.75:1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Page 2610 Rocker Arm Assembly: Service and Repair REMOVAL 1. Remove the cam cover. 2. Position the piston of the cylinder being repaired at the bottom of the stroke. 3. Install the Valve Spring Spacer between the valve spring coils to prevent valve stem seal damage. 4. Use (A) Valve Spring Compressor to compress the (B) valve springs and remove the (C) cam roller followers. INSTALLATION 1. Use (A) Valve Spring Compressor to compress the (B) valve spring and install the (C) camshaft roller followers. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Page 2611 2. Remove Valve Spring Spacer. 3. Install the cam cover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications DIMENSIONS Bearing Wall Thickness (STD): 1.918-1.926 mm Clearance to Crankshaft: Desired: 0.026-0.064 mm Allowable: 0.26-0.064 mm TORQUE SPECIFICATIONS Tighten the connecting rod bolts in two stages, using the sequence shown. ^ Stage 1: 40-45 Nm (29-33 ft. lbs.). ^ Stage 2: Rotate 90-120 degrees. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 2616 Connecting Rod Bearing: Testing and Inspection Inspect the bearings for the following defects. Possible causes are shown: ^ Cratering-fatigue failure (A). ^ Spot polishing-improper seating (B). ^ Scratching-dirty (C). ^ Base exposed-poor lubrication (D). ^ Both edges worn-journal damaged (E). ^ One edge worn-journal tapered or bearing not seated (F). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Bolt Connecting Rod: Specifications Connecting Rod Bolts Stage 1 40-45 Nm (29-33 ft.lb) Use new bolts. Stage 2 Additional 90-120 degrees Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Bolt > Page 2621 Connecting Rod: Specifications Connecting Rod, Engine DIMENSIONS Alignment (Bore-to-Bore Max. Diff.): Twist [1] ............................................................................................................................................... .................................... + 1.27 mm (0.05 inch) Bend ........................................................................... ........................................................................................................ + 0.038 mm (0.0014 inch) Bore Diameter: Crankshaft Bearing: ..................................................................................................................................... 56.866-56.886 mm (2.2383-2.2395 inch) Piston Pin..................................................................................................................................................... 22.012-22.024 mm (0.8665-0.8677 inch) Length: Center-to-Center .................................................................................................................................. ...................................... 150.7 mm (5.93 inch) Side Clearance (Assembled to Crank): Standard ............................................................................................................................................................ 0.015-0.45 mm (0.0006-0.0177 inch) Service Limit ............................................................................. .................................................................................................. 0.50 mm (0.02 inch) [1] Pin bore and crank bearing bore must be parallel and in same vertical plane within the specified total difference when measured at the ends of a 203 mm bar, 101.5 mm on each side of rod centerline.-Twist mm (inch) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Testing and Inspection > Connecting Rod Bearing Journal Clearance Connecting Rod: Testing and Inspection Connecting Rod Bearing Journal Clearance NOTE: The crankshaft connecting rod journals must be within specification to check the connecting rod bearing journal clearance. 1. Remove the connecting rod bearing cap. 2. Position a piece of Plastigage across the bearing surface. 3. Install and torque to specifications, then remove the connecting rod bearing cap. NOTE: Do not turn the crankshaft during this step. 4. Measure the Plastigage to get the connecting rod bearing journal clearance. The Plastigage should be smooth and flat. A changing width indicates a tapered or damaged connecting rod bearing or connecting rod. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Testing and Inspection > Connecting Rod Bearing Journal Clearance > Page 2624 Connecting Rod: Testing and Inspection Connecting Rod Bend Measure the connecting rod bend on a suitable alignment fixture. Follow the instructions of the fixture manufacturer. Verify the bend measurement is within specification. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Testing and Inspection > Connecting Rod Bearing Journal Clearance > Page 2625 Connecting Rod: Testing and Inspection Connecting Rod Bushing Diameter 1. Measure the inner diameter of the connecting rod bushing. Verify the diameter is within specification. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Testing and Inspection > Connecting Rod Bearing Journal Clearance > Page 2626 Connecting Rod: Testing and Inspection Connecting Rod Large End Bore 1. Measure the bore in two directions. The difference is the connecting rod bore out-of-round. Verify the out-of-round is within specification. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Testing and Inspection > Connecting Rod Bearing Journal Clearance > Page 2627 Connecting Rod: Testing and Inspection Connecting Rod Bearing Journal Clearance NOTE: The crankshaft connecting rod journals must be within specification to check the connecting rod bearing journal clearance. 1. Remove the connecting rod bearing cap. 2. Position a piece of Plastigage across the bearing surface. 3. Install and torque to specifications, then remove the connecting rod bearing cap. NOTE: Do not turn the crankshaft during this step. 4. Measure the Plastigage to get the connecting rod bearing journal clearance. The Plastigage should be smooth and flat. A changing width indicates a tapered or damaged connecting rod bearing or connecting rod. Connecting Rod Bend Measure the connecting rod bend on a suitable alignment fixture. Follow the instructions of the fixture manufacturer. Verify the bend measurement is within specification. Connecting Rod Bushing Diameter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Testing and Inspection > Connecting Rod Bearing Journal Clearance > Page 2628 1. Measure the inner diameter of the connecting rod bushing. Verify the diameter is within specification. Connecting Rod Large End Bore 1. Measure the bore in two directions. The difference is the connecting rod bore out-of-round. Verify the out-of-round is within specification. Connecting Rod Piston Pin Side Clearance 1. Measure the clearance between the connecting rod and the piston. Verify the measurement is within specification. Connecting Rod Twist Measure the connecting rod twist on a suitable alignment fixture. Follow the instructions of the fixture manufacturer. Verify the measurement is within specification. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Testing and Inspection > Page 2629 Connecting Rod: Service and Repair CAUTION: Do not use a caustic cleaning solution or damage to connecting rods may occur. NOTE: The connecting rod large end is mechanically split to produce a unique parting face. This produces a locking joint. Parts are not interchangeable. Mark and separate the parts and clean with solvent. Clean the oil passages. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Coolant Drain Plug, Cylinder Block > Component Information > Specifications Coolant Drain Plug: Specifications TORQUE SPECIFICATIONS Cylinder Block Drain Plug ......................................................................................................................................................... 16-24 Nm (11-18 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications DIMENSIONS Bearing Wall Thickness (STD): 2.436-2.454 mm Clearance to Crankshaft: Desired: 0.024-0.048 mm Allowable: 0.024-0.048 mm TORQUE SPECIFICATIONS Tighten the ten main bearing caps bolts in two stages: ^ Stage 1: Tighten to 37-43 Nm (27-32 ft. lbs.) ^ Stage 2: Rotate an additional 85-95 degrees Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 2636 Tighten the ten main bearing cap jack screws in two stages: ^ Stage 1: Tighten to 5 Nm (44.6 inch lbs.) ^ Stage 2: Tighten to 9-11 Nm (80.3-98.1 inch lbs) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 2637 Install the ten cross mounted main bearing cap bolts and tighten in two stages: ^ Stage 1: Tighten to 10 Nm (89.2 inch lbs.) ^ Stage 2: Tighten to 19-23 Nm (14-17 ft. lbs.) NOTE: Refer to the illustrations for proper tightening sequence. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 2638 Crankshaft Main Bearing: Testing and Inspection Inspect the bearings for the following defects. Possible causes are shown: ^ Cratering-fatigue failure (A). ^ Spot polishing-improper seating (B). ^ Scratching-dirty (C). ^ Base exposed-poor lubrication (D). ^ Both edges worn-journal damaged (E). ^ One edge worn-journal tapered or bearing not seated (F). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications DIMENSIONS Free End Play .......................................................................................................................................................... 0.130-0.301 mm (0.0051-0.012 inch) Journal Diameter: Connecting Rod ............................................................................................................................................... 52.988-53.003 mm (2.087-2.867 inch) Main Bearing ..................................................................................................................................................... 67.481-67.505 mm (2.65-2.657 inch) Journal Taper: Connecting Rod ................................................................................................................................... .................................. 0.015 mm (0.0005 inch) Main Bearing ............................................................. ............................................................................................................ 0.020 mm (0.0007 inch) Main Bearing Journal Runout .......................................................................................................................................................... 0.05 mm (0.002 inch) Runout To Rear Block Face .................................................................................................................................................. 0.050 mm (0.002 inch, max) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 2642 Crankshaft: Description and Operation The crankshaft is supported on the bottom of the cylinder block by five steel-backed, overplated aluminum crankshaft main bearings. It also connects with the camshafts by two sprockets and two timing chains. The rear crankshaft thrust washer limits crankshaft end play and absorbs thrust loads applied to the crankshaft ends. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Testing and Inspection > Connecting Rod Taper Crankshaft: Testing and Inspection Connecting Rod Taper Measure the crankshaft connecting rod journal diameters in two directions perpendicular of one another at each end of the connecting rod journal. The difference in the measurements from one end to the other is the taper. Verify measurement is within the wear limit. Undersize connecting rod bearings will need to be installed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Testing and Inspection > Connecting Rod Taper > Page 2645 Crankshaft: Testing and Inspection End Play 1. Use Dial Indicator with Bracketry to measure crankshaft end play. 2. If crankshaft end play exceeds specifications, replace the crankshaft thrust washers or thrust bearing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Testing and Inspection > Connecting Rod Taper > Page 2646 Crankshaft: Testing and Inspection Journal Connecting Rod Journal Diameter Measure the crankshaft connecting rod journal diameters in at least two directions perpendicular of one another. The difference between the measurements is the out-of-round. Verify the journal is within the wear limit specification. Undersize connecting rod bearings will need to be installed. Main Bearing Journal Clearance NOTE: Crankshaft main bearing journals must be within specification before checking journal clearance. 1. Remove the crankshaft main bearing caps and bearings 2. Lay a piece of Plastigage across the face of each crankshaft main bearing surface. 3. Install and remove the crankshaft main bearing cap. NOTE: Do not turn the crankshaft while doing this procedure. 4. Verify the crankshaft journal clearance. ^ If it is out of specification, replace as necessary. Main Bearing Journal Diameter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Testing and Inspection > Connecting Rod Taper > Page 2647 Measure each of the crankshaft main bearing journal diameters in at least two directions. ^ If it is out of specification, replace as necessary. Main Bearing Journal Taper 1. Measure each of the crankshaft main bearing journal diameters in at least two directions at each end of the main bearing journal. 2. If it is out of specification, replace as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Testing and Inspection > Connecting Rod Taper > Page 2648 Crankshaft: Testing and Inspection Runout NOTE: Crankshaft main bearing journals must be within specifications before checking runout. 1. Use Dial Indicator with Bracketry to measure the crankshaft runout. 2. Rotate the crankshaft and subtract the lowest dial indicator reading from the highest dial indicator reading to figure the crankshaft runout. If it is out of specification, replace as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Specifications Engine Block Heater: Specifications TORQUE SPECIFICATIONS Cylinder Block Drain Plug ......................................................................................................................................................... 16-24 Nm (11-18 ft. lbs.) Block Heater Screw .............................................................................................................................................................. 1.6-1.8 Nm (14-16 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Specifications > Page 2652 Engine Block Heater: Description and Operation The block heater: ^ Has a 11OV AC electric heating element. ^ Warms coolant when it is plugged in. ^ Is a mounted plug in the engine block. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Specifications > Page 2653 Engine Block Heater: Service and Repair REMOVAL 1. Drain the cooling system. 2. Disconnect the (A) block heater wire extension from the (B) block heater wiring and remove. 3. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 4. Disconnect the (A) block heater wiring from the (B) block heater. 5. Remove the block heater. ^ Loosen the block heater retaining screw. CAUTION: Do not loosen the block heater retaining screw more than necessary for removal. 2. Twist and slide the block heater to release the retainer clip and remove. Discard the retainer clip. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Specifications > Page 2654 To install, reverse the removal procedure. NOTE: To ease installation, coat the block heater seal and the cylinder block hole with Premium Long Life Grease XG-1-CK or equivalent meeting Ford specification ESA-MlC75-B. If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Expansion/Freeze Plug > Component Information > Service and Repair Expansion/Freeze Plug: Service and Repair REMOVAL 1. Use Slide Hammer to remove the cylinder block core plug. 2. Inspect the cylinder block plug bore for any damage that would interfere with the proper sealing of the plug. If the cylinder block plug bore is damaged, bore for the next oversize plug. NOTE: Oversize plugs are identified by the "OS " stamped in the flat located on the cup side of the plug. INSTALLATION Coat the cylinder block core plug and bore lightly with Thread Lock 262 E2FZ-19554-B or equivalent meeting Ford specification WSK-M2G351-A6 and install the cylinder block core plug. Cup Type ^ Use a fabricated tool to seat the cup type cylinder block core plug. CAUTION: Do not contact the flange when installing a cup type cylinder block core plug. This could damage the sealing edge and result in leakage. When installed, the flanged edge must be below the chamfered edge of the bore to effectively seal the bore. Expansion-Type ^ Use a fabricated tool to seat the expansion type cylinder block core plug. CAUTION: Do not contact the crown when installing a cup type cylinder block core plug. This could expand the plug before seating and result in leakage. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2661 TORQUE SPECIFICATIONS Tighten the crankshaft pulley bolt in four stages. ^ Stage 1: 90 Nm (66 ft. lbs.). ^ Stage 2: Loosen 360 degrees. ^ Stage 3: 47-53 Nm (35-39 ft. lbs.). ^ Stage 4: Rotate 85-90 degrees. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications DIMENSIONS Pin Bore Diameter ............................................................................................................................................... 22.004-22.008 mm (0.866-0.8663 inch) Piston-to-Bore [1]: Clearance .............................................................................................................................................. -0.005 to +0.025 mm (-0.00019 to +0.00038) Ring Groove Width: Compression (Top) ........................................................................................................................................... 1.530-1.550 mm (0.060-0.0610 inch) Compression (Bottom) .................................................................................................................................... 1.520-1.540 mm (0.0593-0.0605 inch) Oil Ring ....................................................................................................... ........................................................ 3.03-3.05 mm (0.1192-0.1207 inch) [1] @ 43 mm from top. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 2665 Piston: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Testing and Inspection > Cleaning and Inspection Piston: Testing and Inspection Cleaning and Inspection CAUTION: Do not use a caustic cleaning solution or a wire brush to clean the pistons or possible damage may occur. 1. Clean and inspect the (A) ring lands, the (B) skirts, the (C) pin bosses, and the (D) top of the pistons. If wear marks or polishing is found on the piston skirt, check for a bent or twisted connecting rod. 2. Use Piston Ring Groove Cleaner to clean the piston ring grooves. ^ Make sure the oil ring holes are clean. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Testing and Inspection > Cleaning and Inspection > Page 2668 Piston: Testing and Inspection Diameter Measure the piston skirt diameter as indicated. Pistons come in three color codes. ^ Coded red (A). ^ Coded blue (B). ^ Coded yellow (c). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Testing and Inspection > Cleaning and Inspection > Page 2669 Piston: Testing and Inspection Pin Bore Diameter WARNING: COVER THE END OF THE PIN BORE WITH A HAND OR SHOP RAG WHEN REMOVING THE RETAINER RING SINCE 11 HAS A TENDENCY TO SPRING OUT. EYE PROTECTION SHOULD BE WORN. NOTE: Piston and piston pins are a matched set and should not be interchanged. ^ Measure the piston pin bore diameter in two directions on each side. Verify the diameter is within specification. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Testing and Inspection > Cleaning and Inspection > Page 2670 Piston: Testing and Inspection Piston Selection NOTE: The cylinder bore must be within specification for taper and out-of-round before fitting a piston. 1. Select a piston size based on the cylinder bore. 2. Choose the piston with the proper paint color. ^ Red-in the lower third of the size range. ^ Blue-in the middle third of the size range. ^ Yellow-in the upper third of the size range. NOTE: For precision fit, new pistons are divided into three categories within each size range based on their relative position within the range. A paint spot on the new pistons indicates the position within the size range. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Testing and Inspection > Cleaning and Inspection > Page 2671 Piston: Testing and Inspection Piston to Cylinder Bore Clearance Subtract the piston diameter from the cylinder bore diameter to find the piston to cylinder bore clearance. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications DIMENSIONS Diameter .................................................................................................................................................... 22.0005-22.0030 mm (0.86616-0.86625 inch) Length ........................................................................ ........................................................................................... 61.601-62.030 mm (2.425-2.442 inch) Pin to Piston Clearance ................................................................................................................................... 0.0009-0.005 mm (0.00073-0.00019 inch) Pin to Rod Clearance ....................................................................................................................................... 0.0093-0.023 mm (0.00036-0.00030 inch) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications > Page 2675 Piston Pin: Testing and Inspection Measure the piston pin diameter in two directions at points shown. Verify the diameter is within specification. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications > Page 2676 Piston Pin: Service and Repair DISASSEMBLY 1. Use Piston Pin Tool to press the piston pin out from the connecting rod and piston assembly. 2. Remove the connecting rod from the piston. 3. Clean and inspect the connecting rod and piston. ASSEMBLY 1. Lubricate the piston pin and piston pin bore. ^ Use engine oil meeting Ford specification WSE-M2C908-A1. 2. Position the piston pin in the bore aligned with the connecting rod bore. NOTE: The connecting rod can be installed in either direction. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications > Page 2677 3. Use Piston Pin Tool to press the piston pin into the piston and rod assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications DIMENSIONS Oil Ring: Side Clearance ................................................................................................................................................. 0.027-0.196 mm (0.0017-0.0077 inch) Compression (Top) ............................................................................................................................................. 0.03-0.08 mm (0.0012-0.0031 inch) Compression (Bottom) .................................................................................................................................... 0.030-0.080 mm (0.0012-0.0031 inch) Ring Gap: Compression (Top) ............................................................................................................................................. 0.13-0.28 mm (0.0051-0.0117 inch) Compression (Bottom) ........................................................................................................................................ 0.25-0.40 mm (0.0093-0.0157 inch) Oil Ring (Steel Rail) ............................................................................................................................................ 0.13-0.28 mm (0.0051-0.0117 inch) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Testing and Inspection > End Gap Piston Ring: Testing and Inspection End Gap CAUTION: Use care when fitting piston rings to avoid possible damage to the piston ring or the cylinder bore. Piston rings should not be transferred from one piston to another. NOTE: Cylinder bore must be within specification for taper and out-of-round to fit piston rings. 1. Use a piston without rings to push a piston ring in a cylinder to the bottom of ring travel. 2. Measure the top piston ring end gap. 3. Measure the 2nd piston ring end gap. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Testing and Inspection > End Gap > Page 2683 Piston Ring: Testing and Inspection Ring to Groove Clearance 1. Inspect for a step in the grooves. 2. Measure the piston ring-to-groove clearance. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Hydraulic lash adjusters provide automatic lash compensation. No adjustment is necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications > Page 2688 Valve Clearance: Adjustments Hydraulic lash adjusters provide automatic lash compensation. No adjustment is necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Locations Fuel Pressure Release: Locations Fuel Pressure Port (Typical) A fuel system service port is provided on the fuel rail. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Locations > Page 2692 Fuel Pressure Release: Service Precautions WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited, resulting in possible injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. - Before repairing or disconnecting any of the fuel lines or fuel system components, the fuel system fuel pressure release procedure must be performed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Locations > Page 2693 Fuel Pressure Release: Service and Repair Fuel Pressure Port (Typical) 1. Remove the schrader valve cap and attach EFI/CFI Fuel Pressure Gauge. 2. Open the manual valve on EFI/CFI Fuel Pressure Gauge and Perform Fuel Pressure Release. NOTE: Open manual value slowly to relieve system pressure. - This will drain some fuel out of the system. - Place fuel in suitable a container. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold Rocker Arm Assembly: Customer Interest Engine - Rough Idle/Noise When Cold Article No. 00-26-1 12/25/00 ^ ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 ^ NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 FORD: 1997-1999 F-250 LD 1997-2000 ECONOLINE, EXCURSION, EXPEDITION, F-150 1999-2000 F SUPER DUTY LINCOLN: 1998-1999 NAVIGATOR ISSUE Some vehicles equipped with a 4.6L, 5.4L, or 6.8L engine may exhibit a rough idle/miss after start-up in cold ambient temperatures (less than -12°C/10 ° F). This may be caused by a roller finger follower(s) being dislodged from the valve. This may result in damage to the camshaft, roller finger follower, valve, retainer, etc. A procedure is now available to service this condition. ACTION Inspect and replace any worn or damaged engine valve components and install new retaining clip and lash adjuster for service. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform normal engine diagnostic routines before opening valve covers. If the valve train is suspect, remove the valve covers and look for Roller Finger Follower(s) (RFF) that may have become dislodged. 1. Inspect the following parts that may have been damaged by any dislodged roller finger followers: ^ Cam lobes (chipped or grooved) ^ Valve stem tips (mushroomed, metal displaced, or bent) ^ Roller finger followers (chipped or grooved) ^ Inspect valve guide only if its corresponding RFF or valve stem tip is damaged. Replace damaged parts as necessary. 2. If follower(s) are damaged, replaced as necessary, otherwise re-use followers in same location as removed from head. 3. Remove all intake and exhaust lash adjusters from the engine and replace with service-only Lash Adjusters (YL3Z-6500-AA). Refer to the appropriate workshop Manual, Section 303-01B for service procedures and tooling necessary to compress the valve springs and remove the roller followers. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2702 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2703 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold Rocker Arm Assembly: All Technical Service Bulletins Engine - Rough Idle/Noise When Cold Article No. 00-26-1 12/25/00 ^ ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 ^ NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 FORD: 1997-1999 F-250 LD 1997-2000 ECONOLINE, EXCURSION, EXPEDITION, F-150 1999-2000 F SUPER DUTY LINCOLN: 1998-1999 NAVIGATOR ISSUE Some vehicles equipped with a 4.6L, 5.4L, or 6.8L engine may exhibit a rough idle/miss after start-up in cold ambient temperatures (less than -12°C/10 ° F). This may be caused by a roller finger follower(s) being dislodged from the valve. This may result in damage to the camshaft, roller finger follower, valve, retainer, etc. A procedure is now available to service this condition. ACTION Inspect and replace any worn or damaged engine valve components and install new retaining clip and lash adjuster for service. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform normal engine diagnostic routines before opening valve covers. If the valve train is suspect, remove the valve covers and look for Roller Finger Follower(s) (RFF) that may have become dislodged. 1. Inspect the following parts that may have been damaged by any dislodged roller finger followers: ^ Cam lobes (chipped or grooved) ^ Valve stem tips (mushroomed, metal displaced, or bent) ^ Roller finger followers (chipped or grooved) ^ Inspect valve guide only if its corresponding RFF or valve stem tip is damaged. Replace damaged parts as necessary. 2. If follower(s) are damaged, replaced as necessary, otherwise re-use followers in same location as removed from head. 3. Remove all intake and exhaust lash adjusters from the engine and replace with service-only Lash Adjusters (YL3Z-6500-AA). Refer to the appropriate workshop Manual, Section 303-01B for service procedures and tooling necessary to compress the valve springs and remove the roller followers. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2709 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2710 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Page 2711 Rocker Arm Assembly: Specifications DIMENSIONS Rocker Arm-Ratio ................................................................................................................................ .................................................................... 1.75:1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Page 2712 Rocker Arm Assembly: Service and Repair REMOVAL 1. Remove the cam cover. 2. Position the piston of the cylinder being repaired at the bottom of the stroke. 3. Install the Valve Spring Spacer between the valve spring coils to prevent valve stem seal damage. 4. Use (A) Valve Spring Compressor to compress the (B) valve springs and remove the (C) cam roller followers. INSTALLATION 1. Use (A) Valve Spring Compressor to compress the (B) valve spring and install the (C) camshaft roller followers. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Page 2713 2. Remove Valve Spring Spacer. 3. Install the cam cover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications Valve Cover: Specifications TORQUE SPECIFICATIONS Tighten the LH cam cover bolts in sequence shown to: 8-12 Nm (71-106 inch lbs.) Tighten the RH cam cover bolts in sequence shown to: 8-12 Nm (71-106 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side Valve Cover: Service and Repair Right Side REMOVAL 1. Disconnect battery ground cable. 2. Disconnect the (A) Positive Crankcase Ventilation (PCV) valve and hose from the (B) cam cover. 3. Lift wiring harness off of cam cover studs. 4. Remove the cam cover bolts and the cam cover. ^ Clean and inspect the mating surface. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2719 1. Apply silicone in two places where the engine front cover meets the cylinder head. ^ Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6. NOTE: Cam cover must be installed within four minutes after silicone is applied. 2. Position the (A) cam cover on the (B) cylinder head and loosely install the cam cover bolts. 3. Tighten the cam cover bolts in the sequence shown. 4. Position the wiring harness onto the cam cover studs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2720 5. Install the (A) PCV valve and tube into the (B) cam cover. 6. Connect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2721 Valve Cover: Service and Repair Left Side REMOVAL 1. Disconnect battery ground cable. 2. Remove the engine Air Cleaner (ACL). 3. Disconnect the power steering fluid reservoir and bracket. 1. Remove the bolts. 2. Position the power steering fluid reservoir and bracket aside. 4. Remove the (A) Positive Crankcase Ventilation (PCV) tube from the (B) cam cover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2722 5. Remove the (A) brake booster vacuum hose bracket nut and the (B) brake booster vacuum hose bracket. 6. Disconnect the EGR connections. ^ Disconnect the two (B) Differential Pressure Feedback (DPPE) EGR transducer hoses. ^ Disconnect the (A) EGR valve to exhaust manifold tube upper fitting. ^ Disconnect the (C) EGR exhaust tube lower fitting and remove the EGR exhaust tube. 7. Lift wiring harness off of the cam cover studs and position aside. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2723 8. Remove the cam cover bolts and the cam cover. ^ Clean and inspect the mating surfaces. INSTALLATION 1. Apply silicone in two places where the engine front cover meets the cylinder head. ^ Use Silicone Gasket and Sealer F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6. NOTE: Cam cover must be installed within four minutes after silicone is applied. 2. Position the (A) cam cover and the cam cover gasket on the (B) cylinder head and loosely install the cam cover bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2724 3. Tighten the cam cover bolts in the sequence shown. 4. Position wiring harness on to cam cover studs. 5. Connect the EGR connections. ^ Two DPPE transducer hoses (A). ^ EGR valve to the exhaust manifold tube upper fitting (B). ^ EGR exhaust tube lower fitting (C). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2725 6. Connect the (A) PCV tube to the (B) cam cover. 7. Install the power steering fluid reservoir bracket. 1. Position the power steering fluid reservoir bracket. 2. Install the bolts. 8. Install the engine air cleaner. 9. Connect battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications Valve Guide: Specifications DIMENSIONS Valve Guide Inner Diameter ................................................................................................................ .................................................... 7.044-7.015 mm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications > Page 2729 Valve Guide: Testing and Inspection 1. Measure the inner diameter of the valve guides in two directions where indicated. 2. If the valve guide is not within specification, ream the valve guide and install a valve with an oversize stem or remove the valve guide and install a new valve guide. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications DIMENSIONS Valve Seat Angle ................................................................................................................................. ......................................................................... 45° Valve Seat Runout (T.I.R.) ............................................................................................................................................... 0.025 mm (0.00038 inch, max) Valve Seat Width: Intake ................................................................................................................................................... ........................ 1.9-2.1 mm (0.074-0.082 inch) Exhaust ..................................................................... ................................................................................................... 1.9-2.1 mm (0.074-0.082 inch) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Testing and Inspection > Runout Valve Seat: Testing and Inspection Runout Use Valve Seat Runout Gauge to check valve seat runout. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Testing and Inspection > Runout > Page 2735 Valve Seat: Testing and Inspection Valve and Seat Refacing Measurements CAUTION: After grinding valves or valve seats, check the valve clearance. 6471-B Check the valve seat and valve angles. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Testing and Inspection > Runout > Page 2736 Valve Seat: Testing and Inspection Width Measure the valve seat width. If necessary, grind the valve seat to specification. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications Valve Spring: Specifications DIMENSIONS Valve Springs-Compression Pressure Intake [1] .............................................................................................................................................. ......................... 633.3-701.3 N (142-158 lbs.) Exhaust [1] .................................................................. ................................................................................................. 633.3-701.3 N (142-158 lbs.) Valve Springs-Free Length (Approximate) Intake ................................................................................................................................................... ...................................... 50.2 mm (1.976 inch) Exhaust ...................................................................... ................................................................................................................ 50.2 mm (1.976 inch) Valve Springs-Installed Pressure Intake [2] .............................................................................................................................................. ............................. 272.1-306.1 N (61-69 lbs.) Exhaust [2] .................................................................. ...................................................................................................... 272.1-306.1 N (61-69 lbs.) Service Limit [1] ................................................................................................................................................ .............................. 3% Pressure Loss Out of Square Limit .............................................................................................................................. ........................................................... 2.5 degrees [1] @ 28.02 mm (1.103 inch) [2] @ 40.0 mm (1.574 inch) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Testing and Inspection > Free Length Valve Spring: Testing and Inspection Free Length Measure the free length of each valve spring. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Testing and Inspection > Free Length > Page 2742 Valve Spring: Testing and Inspection Installed Length Measure the installed length of each valve spring. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Testing and Inspection > Free Length > Page 2743 Valve Spring: Testing and Inspection Squareness 1. Measure the out-of-square on each valve spring. 2. Turn the valve spring and observe the space between the top of the valve spring and the square. Replace the valve spring if out of specification. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Testing and Inspection > Free Length > Page 2744 Valve Spring: Testing and Inspection Strength Use Valve/Clutch Spring Tester to check the valve springs for proper strength at the specified valve spring length. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Testing and Inspection > Page 2745 Valve Spring: Service and Repair REMOVAL 1. Remove the camshaft roller followers. 2. Position the piston at the top of the stroke. 3. Remove the spark plug and install compressed air in the cylinder to hold both valves in position. CAUTION: If air pressure has forced the piston to the bottom of the cylinder any loss of air pressure will allow the valve to fall into the cylinder. If air pressure must be removed support the valve prior to removal. 4. Use Valve Spring Compressor to compress the valve springs. 5. Remove the (A) valve spring retainer keys, (B) valve spring retainers and the (C) valve spring. INSTALLATION 1. Position the (A) valve spring and (B) valve spring retainers. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Testing and Inspection > Page 2746 2. Install the Valve Spring Spacer between the valve spring coils to prevent valve stem seal damage. 3. Use (A) Valve Spring Compressor to compress the (B) valve spring. Install the (C) valve spring retainer keys. 4. Install the camshaft roller followers. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Valve: > 00-26-1 > Dec > 00 > Engine Rough Idle/Noise When Cold Valve: Customer Interest Engine - Rough Idle/Noise When Cold Article No. 00-26-1 12/25/00 ^ ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 ^ NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 FORD: 1997-1999 F-250 LD 1997-2000 ECONOLINE, EXCURSION, EXPEDITION, F-150 1999-2000 F SUPER DUTY LINCOLN: 1998-1999 NAVIGATOR ISSUE Some vehicles equipped with a 4.6L, 5.4L, or 6.8L engine may exhibit a rough idle/miss after start-up in cold ambient temperatures (less than -12°C/10 ° F). This may be caused by a roller finger follower(s) being dislodged from the valve. This may result in damage to the camshaft, roller finger follower, valve, retainer, etc. A procedure is now available to service this condition. ACTION Inspect and replace any worn or damaged engine valve components and install new retaining clip and lash adjuster for service. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform normal engine diagnostic routines before opening valve covers. If the valve train is suspect, remove the valve covers and look for Roller Finger Follower(s) (RFF) that may have become dislodged. 1. Inspect the following parts that may have been damaged by any dislodged roller finger followers: ^ Cam lobes (chipped or grooved) ^ Valve stem tips (mushroomed, metal displaced, or bent) ^ Roller finger followers (chipped or grooved) ^ Inspect valve guide only if its corresponding RFF or valve stem tip is damaged. Replace damaged parts as necessary. 2. If follower(s) are damaged, replaced as necessary, otherwise re-use followers in same location as removed from head. 3. Remove all intake and exhaust lash adjusters from the engine and replace with service-only Lash Adjusters (YL3Z-6500-AA). Refer to the appropriate workshop Manual, Section 303-01B for service procedures and tooling necessary to compress the valve springs and remove the roller followers. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Valve: > 00-26-1 > Dec > 00 > Engine Rough Idle/Noise When Cold > Page 2755 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Valve: > 00-26-1 > Dec > 00 > Engine Rough Idle/Noise When Cold > Page 2756 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold Valve: All Technical Service Bulletins Engine - Rough Idle/Noise When Cold Article No. 00-26-1 12/25/00 ^ ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 ^ NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 FORD: 1997-1999 F-250 LD 1997-2000 ECONOLINE, EXCURSION, EXPEDITION, F-150 1999-2000 F SUPER DUTY LINCOLN: 1998-1999 NAVIGATOR ISSUE Some vehicles equipped with a 4.6L, 5.4L, or 6.8L engine may exhibit a rough idle/miss after start-up in cold ambient temperatures (less than -12°C/10 ° F). This may be caused by a roller finger follower(s) being dislodged from the valve. This may result in damage to the camshaft, roller finger follower, valve, retainer, etc. A procedure is now available to service this condition. ACTION Inspect and replace any worn or damaged engine valve components and install new retaining clip and lash adjuster for service. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform normal engine diagnostic routines before opening valve covers. If the valve train is suspect, remove the valve covers and look for Roller Finger Follower(s) (RFF) that may have become dislodged. 1. Inspect the following parts that may have been damaged by any dislodged roller finger followers: ^ Cam lobes (chipped or grooved) ^ Valve stem tips (mushroomed, metal displaced, or bent) ^ Roller finger followers (chipped or grooved) ^ Inspect valve guide only if its corresponding RFF or valve stem tip is damaged. Replace damaged parts as necessary. 2. If follower(s) are damaged, replaced as necessary, otherwise re-use followers in same location as removed from head. 3. Remove all intake and exhaust lash adjusters from the engine and replace with service-only Lash Adjusters (YL3Z-6500-AA). Refer to the appropriate workshop Manual, Section 303-01B for service procedures and tooling necessary to compress the valve springs and remove the roller followers. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2762 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2763 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Page 2764 Valve: Specifications DIMENSIONS Valve Arrangement (Front-to-Rear) Left Hand ............................................................................................................................................. ................................................ E-I-E-I-E-I-E-I Right Hand ................................................................... ........................................................................................................................ I-E-I-E-I-E-I-E Valve Stem to Guide Clearance Intake ........................................................................................................................................................... 0.020-0.069 mm (0.00078-0.00272 inch) Exhaust .............................................................................................................................................................. 0.046-0.095 mm (0.018-0.0037 inch) Valve Head Diameter Intake ................................................................................................................................................... ........................................ 44.5 mm (1.75 inch) Exhaust ...................................................................... .................................................................................................................. 34.0 mm (1.34 inch) Gauge Diameters .................................................................................................................................................. 42.5 and 32.0 mm (1.67 and 1.26 inch) Valve Face Runout Limit ..................................................................................................................... ............................................ 0.05 mm (0.002 inch) Valve Face Angle ................................................ ........................................................................................................................................... 45.5 degrees Valve Stem Diameter (Std) Intake ................................................................................................................................................... .............. 6.995-6.975 mm (0.275-0.2746 inch) Exhaust .............................................................................................................................................................. 6.970-6.949 mm (0.274-0.2736 inch) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Testing and Inspection > Inspection Valve: Testing and Inspection Inspection Inspect the following valve areas: ^ The end of the stem for grooves or scoring (A). ^ The valve face and the edge for pits, grooves or scores (B). ^ The valve head for signs of burning, erosion, warpage and cracking. Minor pits, grooves and other abrasions may be removed (C). ^ The valve head thickness wear (D). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Testing and Inspection > Inspection > Page 2767 Valve: Testing and Inspection Stem Diameter 1. Measure the diameter of each intake valve stem at the points shown. Verify the diameter is within specification. 2. Measure the diameter of each exhaust valve stem at the points shown. Verify the diameter is within specification. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Testing and Inspection > Inspection > Page 2768 Valve: Testing and Inspection Stem to Guide Clearance NOTE: Valve stem diameter must be within specification before checking valve stem to valve guide clearance. 1. Install Valve Stem Clearance Tool on the valve stem and install Dial Indicator with Bracketry. Lower the valve until Valve Stem Clearance Tool contacts the upper surface of the valve guide. 2. Move the Valve Stem Clearance Tool toward the Dial Indicator and zero the Dial Indicator with Bracketry. Move the Valve Stem Clearance Tool away from the Dial Indicator with Bracketry and note the reading. The reading will be double the valve stem to valve guide clearance. Valves with oversize stems will need to be installed if out of specification. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Testing and Inspection > Inspection > Page 2769 Valve: Testing and Inspection Valve Refacing Measurements CAUTION: After grinding valves or valve seats, check the valve clearance. 6471-B Check the valve seat and valve angles. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams Drive Belt: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 2774 Drive Belt: Description and Operation This engine is equipped with a single drive belt and automatic drive belt tensioner. The accessory drive consists of the: ^ Drive belt. ^ Generator pulley. ^ Power steering pump pulley. ^ Crankshaft vibration damper and pulley. ^ A/C clutch pulley. ^ Belt idler pulley. ^ Drive belt tensioner. ^ Water pump pulley. The accessory drive: ^ Has a single serpentine drive belt. ^ Has automatic tensioning. ^ Is not adjustable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Drive Belt: Initial Inspection and Diagnostic Overview 1. Verify customer concern by running the engine. 2. Inspect the drive belts for chunking, fraying and wear. 3. Check the drive belts for correct routing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2777 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2778 Drive Belt: Component Tests and General Diagnostics Belt Tension NOTE: Drive belt tension is not adjustable. The drive belt tensioner automatically adjusts drive belt tension. Check the automatic drive belt tensioner: 1. With the engine off, check for proper drive belt routing. Service as required. 2. Rotate the drive belt tensioner and check for a binding or frozen condition. Replace components as required. Cracking/Chunking/Wear V-Ribbed Belt With Cracks (Acceptable) V-Ribbed Belt With Chunks Of Rib Missing (Not Acceptable) Under severe operating conditions (high temperatures, low humidity), drive belt rib cracking can occur at less than 48,000 km (30,000 miles). Drive belt rib cracking has no effect on belt performance. Drive belt "chunking" describes a condition when the rubber material actually chunks out between the rib cracks. The drive belt must be replaced if chunking occurs. Drive Belt Misalignment CAUTION: Incorrect drive belt installation will cause excessive drive belt wear and may cause the drive belt to come off the drive pulleys. Non-standard replacement drive belts may track differently or improperly. If a replacement drive belt tracks improperly, replace it with an original equipment drive belt to avoid performance failure or loss of belt. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2779 With the engine running, check drive belt tracking If the (A) edge of the drive belt rides beyond the edge of the pulleys, noise and premature wear may occur. Ensure the (B) drive belt rides correctly on the pulley. If a drive belt tracking condition exists, proceed with the following: Visually check the drive belt tensioner for damage, especially the mounting pad surface. If the drive belt tensioner is not installed correctly, the mounting surface pad will be out of position. This will result in chirp and squeal noises. ^ With the engine running, visually observe the grooves in the pulleys (not the pulley flanges) for excessive wobble. Replace components as required. ^ Check all accessories, mounting brackets and the drive belt tensioner for any interference that would prevent the component from mounting properly. Correct any interference condition and recheck belt tracking. ^ Tighten all accessories, mounting brackets, and drive belt tensioner retaining hardware to specification. Recheck the drive belt tracking. Drive Belt Noise/Flutter NOTE: Tensioner is shown in free-state position against arm travel stops. Drive belt chirp occurs due to pulley misalignment or excessive pulley runout. It can be the result of a damaged pulley or an improperly aligned pulley. To correct, determine the area where the noise comes from. Check each of the pulleys in that area with a straightedge to the crankshaft pulley, look for accessory pulleys out of position in the fore/aft direction or at an angle to the straightedge. Drive belt squeal is an intermittent noise that occurs when the drive belt slips on a pulley during certain conditions, such as engine start up, rapid engine acceleration, or A/C clutch engagement. Drive belt squeal can occur: 1. If the A/C discharge pressure goes above specifications: ^ The A/C system is overcharged. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2780 ^ The A/C condenser core airflow is blocked. 2. If the A/C OFF equalized pressure (the common discharge and suction pressure that occurs after several minutes) exceeds specifications. 3. If any of the accessories are damaged, or have a worn or damaged bearing or internal torsional resistance above normal. All accessories should be rotatable by hand in the unloaded condition. If not, inspect the accessory. 4. If fluid gets on the drive belt. This includes power steering fluid, engine coolant, engine oil or air conditioning system lubricant. If fluid does get on the drive belt during service, clean the drive belt with soap and water and thoroughly rinse with clean water. The drive belt does not have to be replaced if no apparent damage has occurred. 5. If the drive belt is too long. A drive belt that is too long will allow the drive belt tensioner arm to go all the way to the arm travel stop under certain load conditions, which will release tension to the drive belt. If the drive belt tensioner is resting on the stop, replace the drive belt. NOTE: The drive belt tensioner arm should rotate freely without binding. 6. If the drive belt tensioner is worn or damaged. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 2781 Drive Belt: Adjustments NOTE: Drive belt tension is not adjustable. The drive belt tensioner automatically adjusts drive belt tension. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 2782 Drive Belt: Service and Repair REMOVAL 1. Use (B) 1/2 inch square hole in drive belt tensioner pulley hub to rotate (A) drive belt tensioner clockwise and remove the (C) drive belt. INSTALLATION 1. Refer to the drive belt routing illustration for drive belt alignment. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications Drive Belt Tensioner: Specifications TORQUE SPECIFICATIONS Drive Belt Tensioner Bolts .................................................................................................................................................. 21.2-28.8 Nm (16-22 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications > Page 2786 Drive Belt Tensioner: Service and Repair REMOVAL 1. Remove drive belt. 2. Remove (A) drive belt tensioner bolts and (B) drive belt tensioner. INSTALLATION 1. Position the drive belt tensioner and install the bolts. 2. Install drive belt. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2791 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2792 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2793 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2794 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2795 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2796 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2797 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2798 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2799 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2800 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2801 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2802 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2803 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2804 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2805 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2806 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2807 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2808 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2809 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2810 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2811 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2812 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2813 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2814 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2815 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2816 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2817 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2818 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2819 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2820 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2821 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2822 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2823 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2824 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2825 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2826 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2827 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2828 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2829 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2830 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2831 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2832 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2833 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2834 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2835 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2836 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2837 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2838 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2839 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2840 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2841 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2842 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2843 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2844 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2845 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2846 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2847 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2848 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2849 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2850 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2851 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2852 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2853 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2854 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2855 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2856 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2857 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2858 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2859 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2860 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2861 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2862 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2863 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2864 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2865 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2866 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2867 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2868 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2869 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2870 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2871 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2872 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2873 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2874 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2875 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2876 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2877 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2878 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2879 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2880 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2881 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2882 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2883 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2884 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2885 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Page 2886 Engine Mount: Specifications TORQUE SPECIFICATIONS Engine Mount to Block Bolts .............................................................................................................................................. 53-72 Nm (38.9-53 inch lbs.) Engine Mount Pivot Bolt .................................................................................................................................................. 68-92 Nm (49.9-67.6 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > LH Engine Mount: Service and Repair LH REMOVAL 1. Remove the engine cooling fan and the fan shroud. 2. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 3. Remove the LH engine mount to frame mount bolt. 4. Loosen the RH engine mount to frame mount bolt. 5. Lift the engine with a suitable jack. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > LH > Page 2889 6. Remove the LH engine mount to cylinder block bolts and remove the engine mount. INSTALLATION To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > LH > Page 2890 Engine Mount: Service and Repair RH REMOVAL 1. Remove the engine cooling fan and the fan shroud. 2. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE 1tH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 3. Remove the starter motor. 4. Remove the RH engine mount to frame mount bolt. 5. Loosen the LH engine mount to frame mount bolt. 6. Lift the engine with a suitable jack. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > LH > Page 2891 7. Remove the RH engine mount to cylinder block bolts and remove the engine mount. INSTALLATION To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > LH > Page 2892 Engine Mount: Service and Repair Neutralizing Drivetrain Mounts 1. Raise and support the vehicle. 2. Loosen the engine and transmission mounts by loosening the bolts three turns. 3. Lower the vehicle. 4. Operate the vehicle in forward and reverse. 5. Raise and support the vehicle. 6. Tighten the engine and transmission bolts. 7. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Specifications Idler Pulley: Specifications TORQUE SPECIFICATIONS Belt Idler Pulley Bolt ........................................................................................................................................................... 21.2-28.8 Nm (16-22 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Specifications > Page 2896 Idler Pulley: Service and Repair REMOVAL 1. Remove drive belt. 2. Remove (A) belt idler pulley bolt and (B) belt idler pulley. INSTALLATION To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Engine Oil Pressure 40-70 psi Note: Oil temperature at 200 degrees Fahrenheit. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Specifications Engine Oil Dip Stick - Dip Stick Tube: Specifications TORQUE SPECIFICATIONS Oil Indicator Tube Bolt ......................................................................................................................................................... 8-12 Nm (71-107 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Specifications > Page 2904 Engine Oil Dip Stick - Dip Stick Tube: Service and Repair REMOVAL 1. Remove the oil level dipstick. 2. Remove the oil level indicator tube bolt. 3. Remove the oil level indicator tube. 4. Inspect the O-ring for damage. INSTALLATION To install, reverse the removal procedure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Drain Plug > Component Information > Specifications Engine Oil Drain Plug: Specifications TORQUE SPECIFICATIONS Oil Pan Drain Plug ............................................................................................................................... ................................ 11-16 Nm (98-143 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications Technical Service Bulletin # 02-1-9 Date: 020121 Engine Oil - Oil Recommendations/Applications Article No. 02-1-9 01/21/02 ENGINE - ENGINE OIL - RECOMMENDED APPLICATIONS FOR SAE 5W-20 AND SAE 5W-30 MOTOR OILS - GASOLINE AND FLEXIBLE FUEL VEHICLES ONLY FORD: 1992-2002 CROWN VICTORIA 1993-1994 TEMPO 1993-1997 THUNDERBIRD 1993-2002 ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 1998-2002 ESCORT ZX2 2000-2002 FOCUS 1993-1996 BRONCO 1993-1997 AEROSTAR 1993-2002 E SERIES, F-150, RANGER 1995-2002 WINDSTAR 1997-1999 F-250 LD 1997-2001 EXPLORER 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2002 EXCURSION 2001-2002 ESCAPE LINCOLN: 1991-2002 TOWN CAR 1993-1998 MARK VIII 1993-2002 CONTINENTAL 2000-2002 LS 1998-2002 NAVIGATOR MERCURY: 1992-2002 GRAND MARQUIS 1993-1994 TOPAZ 1993-1997 COUGAR 1993-1999 TRACER 1993-2002 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1997-2001 MOUNTAINEER This article is being republished in its entirety to update the vehicle models, engines and years affected. NOTE PLEASE REFER TO THE VEHICLE APPLICATION LIST LATER IN THIS TSB FOR A COMPLETE LIST OF VEHICLES AFFECTED BY THIS TSB. ISSUE Ford Motor Company now recommends SAE 5W-20 viscosity grade for servicing most gasoline and flexible fueled vehicles. ACTION All 2001 and 2002 vehicles where SAE 5W-20 is specified should be serviced at the recommended oil change intervals using SAE 5W-20. This oil is an improved formulation to improve fuel economy. Testing has validated this viscosity grade can be used in many previous model year vehicles. It is recommended ALL vehicles on the following Vehicle Application Listing be service with SAE 5W-20. All 2001-2002 vehicles other than those listed in the "Exception 2001 Vehicles" or "Exception 2002 Vehicles" chart are being filled with SAE 5W-20 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2912 motor oil at the factory and should also be serviced with SAE 5W-20 oil. Exception 2001 Vehicles Exception 2002 Vehicles NOTE IF VEHICLE IS NOT LISTED IN THIS APPLICATION, SAE 5W-30 OIL IS RECOMMENDED. REFER TO TSB 99-8-16. Parts Block OTHER APPLICABLE ARTICLES: 99-8-16 SUPERSEDES: 01-4-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 497000, 499000 Veh. App. Listing Approved For SAE 5W-20 Motor Oil ^ 1993-1996 1.9L Escort/Tracer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2913 ^ 1995-2000 2.0L Zetec Contour/Mystique ^ 1999-2002 2.0L Cougar ^ 1997-2002 2.0L Escort/Tracer ^ 1998-2002 2.0L Escort ZX2 ^ 2000-2002 2.0L Focus ^ 2001-2002 2.0L Escape ^ 1993-1997 2.3L Ranger ^ 1993-1994 2.3L Mustang ^ 1993-1994 2.3L Tempo/Topaz ^ 1998-2001 2.5L Ranger ^ 1995-2000 2.5L Contour/Mystique ^ 1999-2002 2.5L Cougar ^ 2001-2002 3.0L 4V Escape ^ 1996-2001 3.0L 4V Taurus/Sable ^ 1993-2002 3.0L (Vulcan) Aerostar/Ranger, ^ Taurus/Sable (Flexible Fuel and Gas) ^ 1995-2000 3.0L (Vulcan) Windstar ^ 1993-1994 3.0L (Vulcan) Tempo/Topaz ^ 2000-2002 3.0L 4V Lincoln LS ^ 1995-2002 3.8L Windstar ^ 1993-1997 3.8L Taurus/Sable, ^ Thunderbird/Cougar, Continental ^ 1994-2002 3.8L Mustang ^ 2002-2002 3.9L 4V Lincoln LS ^ 1997-2002 4.2L (SPI) F-150 (under 8500 GVW only), E-Series ^ 1996-2002 4.6L 2V Mustang ^ 1992-2002 4.6L Crown Victoria/Grand Marquis ^ 1991-2002 4.6L Town Car ^ 1994-1997 4.6L 2V Thunderbird/Cougar ^ 1996-2002 4.6L 4V Mustang Cobra ^ 1995-2002 4.6L 4V Continental ^ 1993-1998 4.6L 4V Mark VIII Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2914 ^ 1997-2002 4.6L 2V Triton F-150/250 (under 8500 GVW only), E-Series, Expedition ^ 1993-1999 4.9L E-Series, F-Series ^ 1993-1995 5.0L Mustang/Mustang Cobra ^ 1993-1993 5.0L Thunderbird/Cougar ^ 1997-2001 5.0L Explorer/Mountaineer ^ 1993-1996 5.0L E-Series, F-Series, Bronco ^ 2000-2002 5.4L Excursion ^ 1998-2002 5.4L 2V/4V Navigator ^ 1997-2002 5.4L 2V F-1501250 (under 8500 GVW only), Expedition, E-Series, E-350 Chassis/RV/Cutaway ^ 1993-1997 5.8L F-Series, Bronco ^ 1993-1996 5.8L E-Series ^ 2000-2002 6.8L Excursion ^ 1997-2002 6.8L E-Series, E-350 Chassis/RV/Cutaway ^ 1999-2002 6.8L Super Duty F-Series 250 HD/350/450/550 Motorhome ^ 1993-1998 7.5L All Vehicles NOTE FOR 1993 THROUGH 1998 MODEL YEAR FFV USE XO-10W30-FFV. NOTE THE "EXCEPTION 2001-2002 VEHICLES" SHOULD BE SERVICED WITH SAE 5W-30 MOTOR OIL Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2915 Engine Oil: Technical Service Bulletins Motor Oil - Viscosity Grade Recommendation Article No. 99-8-16 05/03/99 MOTOR OIL - SAE VISCOSITY GRADE RECOMMENDATION - SERVICE TIP FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-1999 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-1999 CONTOUR LINCOLN-MERCURY: 1989-1992 MARK VII 1989-1994 TOPAZ 1989-1997 COUGAR 1989-1999 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1991-1994 CAPRI 1994-1998 MARK VIII 1995-1999 MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-1999 ECONOLINE, F-150, F-250 LD, RANGER 1991-1999 EXPLORER 1993-1999 VILLAGER 1995-1999 WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE Ford Motor Company now recommends SAE 5W-30 viscosity grade for servicing any Ford gasoline-powered vehicle regardless of model year. ACTION When servicing any Ford gasoline-powered vehicle, use SAE 5W-30 viscosity grade motor oil. Refer to the following text for further details. Both SAE 10W-30 and SAE 5W-30 viscosity grade motor oils have been recommended in the past depending on vehicle model and model year. Tests have proven SAE 5W-30 viscosity grade motor oil provides the optimum protection and benefits for Ford gasoline engines. At both high and low ambient temperature conditions, SAE 5W-30 provides the best overall protection. It allows faster starts under cold ambient temperatures. SAE 5W-30 also provides approximately 1/2% increase in fuel economy over SAE 10W-30. SAE 5W-30 viscosity grade motor oils certified for gasoline engines by the American Petroleum Institute (API) should be used for all service procedures requiring replacement of the motor oil. PART NUMBER PART NAME XO-5W30-QSP 5W-30 Motorcraft Super Premium Motor Oil OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 499000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2916 Engine Oil: Technical Service Bulletins Engine - Oil Level Checking Incorrect in Owner's Guide Article No. 97-6-26 03/17/97 ^ ENGINE - CHECKING ENGINE OIL LEVEL IN OWNER'S GUIDE INCORRECT ^ OIL - CHECKING ENGINE OIL LEVEL IN OWNER'S GUIDE INCORRECT LIGHT TRUCK: 1997 EXPEDITION ISSUE: The oil level indicator illustration shown in the Service Section on Page 161 of the 1997 Expedition Owner's Guide is incorrect. ACTION: Inform customers who own the subject vehicle that the illustration is incorrect and show them the correct way to check the oil level. Refer to the following text for more details. The current Owner's Guide shows an illustration of the oil level indicator as being marked "ADD-FULL," which is incorrect. The illustration should read "MIN-MAX." The oil level should read between the "MIN-MAX" level on the indicator. If the level falls below "MIN," add oil as necessary to return the oil level to between the "MIN-MAX" level. Do not exceed the "MAX" mark or engine damage may occur. The following Steps will be printed in all subsequent Owner's Guides using "MIN-MAX" oil level indicators: 1. Make sure the vehicle is on level ground. 2. Turn off the engine and wait a few minutes for the oil to drain back into the oil pan. 3. Set the parking brake and make sure the gearshift is securely latched in "P" (automatic) or 1st gear (manual). 4. Open the hood. Protect yourself from engine heat. 5. Locate and carefully remove the engine oil level indicator (dipstick). 6. Wipe the indicator clean. 7. Insert the indicator fully and remove it again. a. If the oil level is between the "MIN-MAX" marks, the oil level is acceptable. DO NOT ADD OIL. b. If the oil level is below the "MIN" mark, add enough oil to raise the level to within the "MIN-MAX" marks. CAUTION: OIL LEVELS ABOVE THE "MAX" MARK MAY CAUSE ENGINE DAMAGE. SOME OIL MUST THEN BE REMOVED BY A SERVICE TECHNICIAN. 8. Put the indicator back in and make sure it is fully seated. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil Capacity ............................................................................................................................................... ............................................................. 5.7L (6.0 Qt) NOTE: Listed capacities are approximate. Check fluid level after filling. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2919 Engine Oil: Fluid Type Specifications Engine Oil Type Type ..................................................................................................................................................... .......................................................................... GF-1 Viscosity .............................................................................................................................................. ...................................................................... 5W-30 NOTE: Must meet Ford Specification M2C-153-F Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Specifications Oil Cooler: Specifications TORQUE SPECIFICATIONS Oil Cooler ............................................................................................................................................. ..................................... 55-60 Nm (40-44 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Specifications > Page 2923 Oil Cooler: Service and Repair REMOVAL 1. Raise and support vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Drain coolant. 3. Loosen the oil cooler to oil filter adapter bolt, and remove the oil cooler. 4. Slide hose clamps down and disconnect the coolant hoses from the oil cooler. 5. Remove the bolts and remove the oil cooler from the remote oil filter adapter. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Specifications > Page 2924 INSTALLATION 1. Position the remote oil filter adapter lines and install the nuts. 2. Position the oil cooler and install the bolt. 3. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. 4. Fill the engine coolant. 5. Check the oil level and fill to specie cation with Ford Premium SAE 10W-30 Motor Oil XO-1OW-30-BSP, DSP, QSP or equivalent meeting Ford specification ESE-M2C153-E. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications Oil Filter: Specifications TORQUE SPECIFICATIONS Oil Filter ............................................................................................................................................... ................................... 14-17 Nm (10-12.5 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Specifications Oil Filter Adapter: Specifications TORQUE SPECIFICATIONS Oil Filter Adapter Bolts .......................................................................................................................................................... 20-30 Nm (14.7-22 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter Oil Filter Adapter: Service and Repair Oil Filter Adapter REMOVAL 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Disconnect the lower radiator hose from the oil filter adapter. 3. If equipped, remove the oil cooler. 4. Remove the oil filter. 5. Disconnect the oil pressure switch electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter > Page 2933 6. If equipped with a remote oil filter adapter, remove the nuts and disconnect the remote oil filter adapter. 7. Remove the three oil filter adapter bolts and the nut, and the oil filter adapter. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter > Page 2934 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter > Page 2935 INSTALLATION 1. To install, reverse the removal procedure. 2. Check the oil level and fill to specification with Ford Premium SAE 1OW-30 Motor Oil XO-1OW-30-BSP, DSP, QSP or equivalent meeting Ford specification ESE-M2C153-E. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter > Page 2936 Oil Filter Adapter: Service and Repair Remote Adapter REMOVAL 1. Raise and support the vehicle WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Remove the drain plug and drain the engine oil. 3. If equipped with an oil cooler, remove the two nuts and disconnect the remote oil filter adapter from the oil cooler. 4. If vehicle is not equipped with an oil cooler, disconnect the oil pressure switch electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter > Page 2937 5. Remove the two nuts and disconnect the remote oil filter adapter. 6. Remove the oil filter. 7. Remove the two bolts, and remove the remote oil filter adapter. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter > Page 2938 INSTALLATION To install, reverse the removal procedure. ^ Fill engine with Ford Premium SAE 1OW-30 Motor Oil XO-1OW-30-BSP, DSP, QSP or equivalent meeting Ford specification ESE-M2C153-E. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications TORQUE SPECIFICATIONS Tighten the 16 oil pan bolts in the sequence shown. ^ Stage 1: 2 Nm (18 inch lbs.) ^ Stage 2: 20 Nm (15 ft. lbs.) ^ Stage 3: Rotate 60 degrees. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2942 Oil Pan: Description and Operation The oil pan: ^ Is stamped steel, electrocoat-painted and bolts to the bottom of the engine cylinder block. ^ Acts as a reservoir, holding lubrication that is pumped through the engine by the oil pump after engine start-up. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2943 Oil Pan: Service and Repair REMOVAL 1. Remove the front axle housing. 2. Remove the drain plug and drain the engine oil. 3. Remove the oil pan bolts. 4. Remove the oil pan and oil pan gasket. INSTALLATION 1. Clean the mating surfaces. 2. Apply silicone at the rear oil seal retainer to block sealing surface. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2944 ^ Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6. NOTE: Oil pan must be installed within four minutes after applying silicone. 3. Apply silicone at the front cover to block sealing surface. ^ Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6. 4. Install the oil pan gasket and the oil pan, and loosely install the sixteen oil pan bolts. 5. Tighten the oil pan bolts in the sequence shown. NOTE: Make sure to tighten the oil pan bolts in three steps. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2945 6. Tighten the oil pan bolts in the sequence shown. 7. Tighten the oil pan bolts in the sequence shown. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2946 8. Install oil drain plug. 9. Install the front axle housing. 10. Fill the engine with oil. ^ Use engine oil meeting Ford specification WSE-M2C903-A1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Testing and Inspection Oil Pressure Gauge: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Switch (For Fuel Pump) > Component Information > Specifications Oil Pressure Switch (For Fuel Pump): Specifications Oil Pressure Switch 12-16 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Switch (For Fuel Pump) > Component Information > Specifications > Page 2953 Oil Pressure Switch (For Fuel Pump): Testing and Inspection To avoid potential misdiagnosis and the unnecessary replacement of components, it is recommended that diagnosis and testing begin with Diagnostic Routines (Diagnosis by Symptom) at the Powertrain Management level. The Diagnostic Routines will lead the technician through the logical and methodical testing of a "specific" subsystem and it's related wiring and components. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Switch (For Fuel Pump) > Component Information > Specifications > Page 2954 Oil Pressure Switch (For Fuel Pump): Service and Repair REMOVAL 1. Disconnect the oil pressure switch electrical connector. 2. Remove the oil pressure switch from the oil filter adapter. INSTALLATION 1. To install, reverse the removal procedure. 2. Check the oil level and fill to specification with Ford Premium SAE 1OW-30 Motor Oil XO-1OW-30-BSP, DSP, QSP or equivalent meeting Ford specification ESE-M2C153-E. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump Cover > Component Information > Specifications Oil Pump Cover: Specifications TORQUE SPECIFICATIONS Screen/Cover Bolt ............................................................................................................................... .................................... 8-12 Nm (71-107 inch lbs.) Screen/Cover Spacer .......................................... ..................................................................................................................... 20-30 Nm (14.7-22 ft. lbs.) Screen/Cover Spacer Bolt ....................................................................................................................................................... 20-30 Nm (14.7-22 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump Cover > Component Information > Specifications > Page 2958 Oil Pump Cover: Service and Repair REMOVAL 1. Remove the oil pan. 2. Remove the (A) three oil pump screen and cover bolts and the (B) oil pump screen and cover. 3. Remove the oil pump screen and cover spacer. INSTALLATION 1. Clean and inspect the mating surfaces. 2. Install the oil pump screen and cover spacer. 3. Install the oil pump screen and cover and install the three oil pump screen and cover bolts. 4. Install the oil pan. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Specifications Oil Pick Up/Strainer: Specifications TORQUE SPECIFICATIONS Screen/Cover Bolt ............................................................................................................................... .................................... 8-12 Nm (71-107 inch lbs.) Screen/Cover Spacer .......................................... ..................................................................................................................... 20-30 Nm (14.7-22 ft. lbs.) Screen/Cover Spacer Bolt ....................................................................................................................................................... 20-30 Nm (14.7-22 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Specifications > Page 2962 Oil Pick Up/Strainer: Service and Repair REMOVAL 1. Remove the oil pan. 2. Remove the (A) three oil pump screen and cover bolts and the (B) oil pump screen and cover. 3. Remove the oil pump screen and cover spacer. INSTALLATION 1. Clean and inspect the mating surfaces. 2. Install the oil pump screen and cover spacer. 3. Install the oil pump screen and cover and install the three oil pump screen and cover bolts. 4. Install the oil pan. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Engine Oil Pressure 40-70 psi Note: Oil temperature at 200 degrees Fahrenheit. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications Intake Manifold: Specifications TORQUE SPECIFICATIONS Tighten the lower intake manifold bolts in two stages, in the sequence shown: ^ Stage 1: 2 Nm (18 inch lbs.). ^ Stage 2: 8-12 Nm (71-106 inch lbs.). Tighten throttle body bolts to 8-10 Nm (71-89 inch lbs.). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2970 Intake Manifold: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal Intake Manifold: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove air cleaner assembly. 3. Relieve the fuel pressure. 4. Drain the cooling system. 5. Compress and slide the (A) hose clamp and disconnect the (B) upper radiator hose. 6. Remove the snap-in-end fitting from the accelerator cable bracket. 7. Disconnect accelerator cable from the throttle body cam. a. Roll the throttle body cam forward. b. Slide accelerator cable end from the throttle body cam. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2973 8. Disconnect throttle return spring from throttle body cam. 9. If equipped, remove the speed control actuator cable from the throttle body. a. Remove the speed control actuator cable to accelerator cable bracket bolt. b. Disconnect the (A) speed control actuator cable from the (B) throttle body cam and position aside. 10. Disconnect the throttle body hose connections. ^ Vapor management valve (VMV) hose (A). ^ Engine vacuum reservoir hose (B). ^ Positive crankcase ventilation (PCV) hose (C). ^ Brake booster hose (D). 11. Remove the (A) brake booster vacuum hose bracket nut and the (B) brake booster vacuum hose bracket. 12. Disconnect the fuel lines. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2974 13. Disconnect the following electrical connectors: ^ Idle air control valve (IAC valve) electrical connector (A). ^ Differential pressure feedback EGR (DPFE) transducer electrical connector (B). ^ Engine vacuum regulator (EVR) electrical connector (C). ^ Throttle position (TP) sensor electrical connector (D). 14. Disconnect the EGR connections. ^ Two DPFE transducer hoses (B). ^ EGR valve to exhaust manifold tube upper fitting (A). ^ EGR valve to exhaust manifold tube lower fitting and remove the EGR exhaust tube (C). 15. Disconnect the following vacuum connections: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2975 ^ EGR vacuum connection (A). ^ VMV vacuum connection (B). ^ Fuel pressure regulator vacuum connection (C). ^ EVR vacuum connection (D). 16. Disconnect the RH fuel injector electrical connectors. 17. Disconnect the LH fuel injector electrical connectors. 18. Disconnect the eight spark plug wires, if necessary. 19. Remove the drive belt. 20. Remove the generator (GEN). 21. Disconnect the following electrical connections: ^ Engine coolant temperature sensor (ECT sensor) electrical connector (A). ^ Water temperature indicator sending unit electrical connector (B). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2976 22. Remove the (A) three power steering fluid reservoir bracket bolts and the (B) power steering bracket. 23. Compress and slide the (A) hose clamp back and disconnect the (B) heater water hose. 24. Remove the intake manifold bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2977 25. Remove the intake manifold. a. Lift the intake manifold. b. Disconnect the intake manifold tuning valve (IMTV) electrical connector. c. Remove and discard the upper intake manifold gaskets. 26. Remove the lower intake manifold bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2978 27. Separate the (A) upper intake manifold from the (B) lower intake manifold and (C) discard the lower intake manifold gasket. 28. Remove the (A) NVH push pin from the (B) NVH shield and remove the NVH shield from the (C) lower intake. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2979 Intake Manifold: Service and Repair Installation 1. Install the (B) NVH shield on the (C) lower intake manifold and install the (A) NVH push pin. 2. Position the (C) lower intake manifold gasket and the (A) upper intake manifold on the (B) lower intake manifold and loosely install eight the lower intake manifold bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2980 3. Tighten the lower intake manifold bolts in the sequence shown. NOTE: Make sure to tighten the lower intake manifold bolts in two steps. 4. Tighten the lower intake manifold bolts in the sequence shown. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2981 5. Install the upper intake manifold. a. Position the upper intake manifold gaskets. b. Position the upper intake manifold. c. Loosely install the nine intake manifold bolts. 6. Connect the IMTV electrical connector. 7. Position the (A) thermostat housing and start the two (B) thermostat housing bolts. NOTE: Check that the thermostat is in the correct position before thermostat housing is installed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2982 8. Tighten the intake manifold bolts in the sequence shown. NOTE: Make sure to tighten the intake manifold in two steps. 9. Tighten the intake manifold bolts in the sequence shown. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2983 10. Install the (B) heater water hose and position the (A) clamp. 11. Position the (A) power steering bracket and install the (B) three power steering pump bracket bolts. 12. Connect the following electrical connections: ^ ECT sensor electrical connector (A). ^ Water temperature indicator sending unit electrical connector (B). 13. Install the generator. 14. Install the drive belt. 15. Connect the eight spark plug wires, if necessary. 16. Connect the four LH fuel injector electrical connectors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2984 17. Connect the four RH fuel injector electrical connectors. 18. Connect the following vacuum connections: ^ EGR vacuum connector (A). ^ VMV vacuum connector (B). ^ Fuel pressure regulator vacuum connector (C). ^ EVR vacuum connector (D). 19. Connect the EGR connections: ^ Two DPFE transducer hoses (A). ^ EGR valve to exhaust manifold tube upper fitting (B). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2985 ^ EGR valve to exhaust manifold tube lower fitting (C). 20. Connect the following electrical connections: ^ IAC valve electrical connector (A). ^ DPFE transducer electrical connector (B). ^ EVR electrical connector (C). ^ TP sensor electrical connector (D). 21. Connect the fuel lines. 22. Position the (A) brake booster vacuum hose bracket and install the (B) brake booster vacuum hose bracket nut. 23. Install the following throttle body hose connections. ^ VMV hose (A). ^ Engine vacuum reservoir hose (B). ^ PCV Hose (C). ^ Brake booster vacuum hose (D). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2986 24. If equipped, install the speed control actuator cable on the throttle body. a. Install the speed control actuator cable to accelerator cable bracket bolt. b. Connect the (A) speed control actuator cable to the (B) throttle body cam. 25. Install throttle return spring on to throttle body cam. 26. Connect accelerator cable to throttle body cam. a. Rotate throttle body cam forward. b. Slide accelerator end into throttle body cam. 27. Press the snap-in-end fitting in the accelerator cable bracket. 28. Install the engine air cleaner outlet tube. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2987 29. Install the (B) upper radiator hose and position the (A) clamp. 30. Fill the cooling system. 31. Connect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven l6 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Testing and Inspection Oil Pressure Gauge: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Specifications Crankshaft Main Bearing Seal: Specifications TORQUE SPECIFICATIONS Rear Oil Seal Retainer Bolt .................................................................................................................................................... 8-12 Nm (71-107 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Specifications > Page 2996 Crankshaft Main Bearing Seal: Service and Repair REMOVAL 1. Remove the transmission. 2. Remove the oil pan. 3. Remove the flywheel. 4. Use the (A) Rear Crankshaft Slinger Remover and the (B) Slide Hammer to remove the (C) rear oil seal slinger. 5. Use the (A) Rear Crankshaft Seal Remover and the (B) Slide Hammer to remove the (C) rear main seal. 6. Remove the six crankcase rear oil seal retainer bolts and the crankcase rear oil seal retainer. INSTALLATION 1. Clean and inspect the mating surface. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Specifications > Page 2997 2. Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6. NOTE: The rear oil seal retainer must be installed within four minutes after applying silicone. The silicone must be applied on the groove along the retainer plate. 3. Install the rear oil seal retainer and loosely install the bolts. 4. Tighten the rear oil seal retainer bolts in the sequence shown. 5. Use the Rear Crankshaft Seal Replacer and the Rear Crankshaft Seal Adapter to install the rear main seal. NOTE: Lubricate inner lip of rear crankshaft seal with engine oil meeting Ford specification WSE-M2C908-A1. 6. With the Rear Crankseal Adapter still installed, use the Rear Crankshaft Slinger Replacer and the Rear Crankshaft Seal Replacer to install the rear Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Specifications > Page 2998 main seal slinger. 7. Install the flywheel. 8. Install the oil pan. 9. Install the transmission. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification Cylinder Head Gasket: Technical Service Bulletins Engine - Reman Engine Head Gasket Identification TSB 06-18-16 09/18/06 IDENTIFYING THE CORRECT REPLACEMENT HEAD GASKET FOR CERTAIN REMANUFACTURED ENGINES - SERVICE TIP FORD: 1999-2006 Mustang, Mustang, Mustang, Mustang, Mustang, Mustang 2000-2005 Thunderbird 2001-2005 Taurus 2001-2006 Crown Victoria, Crown Victoria 2005 Five Hundred, Freestyle 1997-2005 Expedition 1997-2006 E-Series, Explorer, F-150, F-Super Duty 1999-2003 Windstar 1999-2004 F-53 Motorhome Chassis 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Escape, Escape, Explorer Sport Trac, Ranger 2004-2005 Freestar, Freestar 2006 F-53 Motorhome Chassis LINCOLN: 2000-2006 Lincoln LS 2001-2002 Continental 2001-200 Town Car 1998-2004 Navigator, Navigator 2003-2004 Aviator 2006 Mark LT MERCURY: 2001 Cougar 2001-2005 Sable 2001-2006 Grand Marquis 2003-2006 Marauder 2005 Montego 1997-2006 Mountaineer 2004-2005 Monterey 2005 Mariner ISSUE On various vehicles when servicing the head gasket on certain Ford remanufactured engines, it is critical to determine the type of remanufactured engine that is being serviced, in order to identify the correct replacement gasket. ACTION Follow the Service Procedure to help identify if the vehicle is equipped with a SID (for originally equipment level thickness head gasket) or OVR (for oversized service level thicker head gasket) remanufactured engine when replacing a head gasket. SERVICE PROCEDURE Use this TSB to help identify if the vehicle is equipped with a STD or OVR remanufactured engine when replacing a head gasket. This will ensure that you obtain the proper head gasket (thicker for OVR-oversized) for the engine you are repairing, as the engine may have milled engine block deck, milled cylinder head deck, or an over sized bore in the cylinders. This information will be needed when ordering parts. The parts catalogs already reflect the correct service numbers, as long as this additional information is available. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 3003 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 3004 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 3005 For certain remanufactured engines, the long block assembly will be uniquely identified with a build date, reman code, service part number, and serial number. This metal tag will be marked with STD, or with OVR (Figures 1-6). WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 3006 Technical Service Bulletin # 02-1-4 Date: 020121 Engine Head Gasket - Approved Replacement Procedures Article No. 02-1-4 01/21/02 ENGINE - APPROVED HEAD GASKET REPLACEMENT SERVICE PROCEDURES FORD: 1992-1997 THUNDERBIRD 1992-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 2000-2002 FOCUS 1995-2002 WINDSTAR 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE LINCOLN: 1992-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1992-1997 COUGAR 1992-1999 TRACER 1992-2002 GRAND MARQUIS, SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER ISSUE Some engine assemblies with aluminum cylinder heads repaired in-vehicle have been found to leak coolant and/or oil from the cylinder head gasket area due to particle contamination or scratches and dents at the head to block mating surfaces. ACTION Refer to the following Service Information for recommended gasket sealing surface preparation procedures. If the engine diagnosis points to a faulty head gasket (leaks oil, leaks coolant, oil or coolant contamination, or air in coolant), thorough cleaning procedures are necessary for a successful head gasket repair. Diagnosis and post-repair confirmation can be done successfully utilizing leak detection methods such as a black light dye process. SERVICE PROCEDURE To sum up, a successful leak repair depends on: ^ Accurate diagnosis of the leak using Ford-recommended test equipment and procedures ^ Surface preparation and gasket installation using the approved tools, cleaners, and methods ^ Exercising CARE and CLEANLINESS during disassembly/assembly of components ^ Use of genuine Ford OEM replacement parts ^ Use of a Ford Remanufacturer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 402000, 403000, 499000 Aluminum Cylinder Head - Removal From Engine Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 3007 WARNING ALUMINUM CYLINDER HEADS ARE HIGHLY POLISHED AND MUST BE HANDLED WITH EXTREME CARE. AFTER REMOVING THE HEAD BOLTS, WITHDRAW THE HEAD FROM THE ENGINE COMPARTMENT. USE EXTREME CARE NOTING THAT THE GASKET SURFACE OF THE HEAD COULD BE DAMAGED ON THE WAY OUT OF THE VEHICLE IF ALLOWED TO HIT AGAINST OTHER ENGINE COMPONENTS. ONCE REMOVED, PLACE THE HEAD ON A BENCH, GASKET SIDE UP, USING A PIECE OF CLEAN CARDBOARD ON THE BENCH SURFACE UNDERNEATH. DO NOT SLIDE THE HEAD GASKET SURFACE ALONG THE BENCHTOP OR DAMAGE WILL OCCUR. NOTE SOME ENGINES REQUIRE A "DE-TORQUING" PROCEDURE OF THE CYLINDER HEAD BOLTS. CONSULT WITH THE APPROPRIATE MODEL YEAR WORKSHOP MANUAL FIRST, AS THIS PROCEDURE IS USUALLY DONE ON FOUR-VALVE ENGINES. HOWEVER, ALL ALUMINUM HEADS ARE PRONE TO WARPAGE DURING REMOVAL IF TAKEN OFF WHEN HOT OR WARM. THE ENGINE SHOULD BE COOLED SUFFICIENTLY BY THE TIME THE HEADS ARE ACCESSIBLE DURING TEARDOWN. ALLOW AN ADEQUATE COOL DOWN PERIOD. NOTE IN SOME ENGINE APPLICATIONS, IT MAY BE NECESSARY TO "RUBBER BAND" A FEW OF THE HEAD BOLTS TOGETHER DUE TO TIGHT CLEARANCES OF THE HEAD NEAR HEATER/AC PLENUMS AND THE BODY COWL. THIS WILL ALLOW THE BOLTS TO CLEAR THE BLOCK DECK AS THE HEAD IS WITHDRAWN FROM THE VEHICLE. Place CLEAN shop towels over the cylinder block bores to prevent further contamination from reaching internal parts and surfaces. If a towel is to be removed, do it SLOWLY . Debris collected on the towel can fall on the engine if care is not exercised as it is removed. Gasket surfaces are machined to near-mirror surface quality. Scratches, dents, gouges, and other impressions may allow oil, coolant, and compression gases to leak into other sealed cavities and/or the atmosphere. Surface imperfections deteriorate the head gasket's ability to seal effectively. Contamination on these surfaces will cause leaks from "shimming" the head even under full head bolt torque. Contamination will also cause marks on the polished gasket surface, creating a leak path. Inspection For Damage and Cleaning Procedure The overall straightness of the cylinder head and block face is held within very tight specification. Defects known as "waviness" or "depressions" cannot be surface machined out with ordinary equipment. Machining must meet manufacturer's specification on surface finish quality and be less than 0.001" inch (0.025 mm) level as measured under a known quality straightedge using a feeler gauge. If the engine has been overheated the cylinder head may have been damaged or warped. Re-surfacing will not correct this damage. The head must not contain any impressions on its sealing surface deeper than 0.001" (0.025 mm). There must not be any scratches or gouges present, especially those which track to another sealing cavity or to the atmosphere. Ensure that the mating cylinder block surface is completely free of solid contamination, corrosion, and fluids. Use Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA or equivalent, to rid the surface of any material, which could later interfere with the gasket's sealing ability. WARNING UNDER NO CIRCUMSTANCES ARE ANY ALUMINUM GASKET SURFACES TO BE CLEANED USING RAZOR BLADES, ROTARY ABRASIVE DEVICES INCLUDING ROLOC AND 3M BRANDED SCOTCHBRITE PRODUCTS, ROTARY WIRE BRUSHES, SINGLE HANDLED WIRE BRUSHES, HAND ABRASIVE SUCH AS SANDPAPER OR EMERY CLOTH, OR ANY CARBON STEEL BLADE. THESE TOOLS ARE PROVEN TO CUT AND DAMAGE ALUMINUM AND WILL DISRUPT THE POLISHED FINISH. ABRASIVE PARTICLES ARE ALSO SUSCEPTIBLE TO ENTERING THE ENGINE CAVITIES AND MAY CAUSE INTERNAL ENGINE DAMAGE. THE ONLY TOOLS ACCEPTABLE ARE PLASTIC AND WOOD SCRAPERS COMBINED WITH USE OF MOTORCRAFT METAL SURFACE CLEANER, F4AZ-19A536-RA, OR EQUIVALENT SOLVENT. The original head bolts are to be discarded. Only new head bolts are acceptable for use in a head gasket repair. Use of old bolts can cause clamp load failure because they were stretched from the last torquing procedure either from the plant or a previous field repair. The new head bolt shanks and threads should be thoroughly cleaned, dried, and lightly lubricated. Oil the bolts and let oil drip for a minimum of 5 minutes. Use of too much oil may cause hydraulic lockup in the bolt hole. The corresponding bolt holes in the cylinder block must be free of contamination consisting of dirt particles, coolant, and oil. Bolts can mechanically or hydraulically lock on top of these materials and cause for poor clamping of the cylinder head gasket. Use very lightly compressed air to blow out the bolt holes. Use care to prevent debris from scattering over the internal engine surfaces. To clean the cylinder block gasket surface, a plastic or wood scraper in combination with Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA, or equivalent solvent can be used with a portable shop vacuum. Move the scraper toward the vacuum nozzle to direct loosened material quickly away from the block surface. It is not necessary to expect aluminum head surfaces to be shiny and bright after the vehicle has been in service. Sanding, scraping, or polishing will create surface depressions that cause leaks. The surface is expected to be flat within 0.001" (0.025 mm) and free of dirt, metal chips, and liquid contaminants. Any staining of the metal surface is considered normal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 3008 Machining of aluminum heads and blocks is an unacceptable field practice for quality control purposes of flatness and surface finish standards. Removing material will also raise the risk of internal reciprocating components striking each other, as well as changing the emissions calibration of the engine. Machining practices of aluminum blocks and heads are not reimbursable. Ford Remanufacturers are authorized to perform this procedure and have the necessary equipment to put the specified surface finish on the head within original factory limits. Installation Onto the Cylinder Block Surface WARNING ANY GASKET SEALING AIDS WHICH ARE NOT LIMITED TO, AND INCLUDE AVIATION CEMENT, COPPER SPRAYS, OR GLUES ARE NOT TO BE USED. THE GASKET MUST BE FITTED DRY WITHOUT SUPPLEMENTAL SEALING AIDS. ATTEMPTS TO SEAL WITH THESE COMPOUNDS WILL CAUSE HEAD SHIMMING AND/OR NEW LEAK PATHS. THESE COMPOUNDS HAVE ALSO BEEN KNOWN TO CAUSE EMISSIONS SENSORS TO FAIL THEREBY TRIPPING FAULT CODES IN THE PCM. Ensure that all surfaces of the cylinder block, cylinder head, and gasket are fully free of any solid or liquid contamination and have been prepared for assembly using Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA, or equivalent solvent. Also ensure that any residual dirt on the engine was removed successfully from the surrounding areas of the block to head face of the head and the block. Using Workshop Manual procedures, assemble the head to the block carefully. Do not allow the gasket surfaces to scrape or bang against other engine parts. The head may pick up material along the way, if this is allowed. Once in place, with dowels properly aligned to the head and ensuring that the head is fully square, seated, and resting on the block deck in a level condition, install new "torque-to-yield" cylinder head bolts to a finger tight condition. Refer to the appropriate model year Workshop Manual for the procedure to torque the head bolts in the correct sequence and at the intervals specified. Failure to follow these instructions may result in a warped head, and damaged head bolt threads. Do not use "cheater pipes" on torque wrenches. Use a known quality, calibrated torque wrench. Pull evenly and steady on each bolt. Do not exert side pressures on the bolt hex, which can disrupt the integrity of the bolt head and give a false reading on the final torque value of the fastener. Once the engine is fully reassembled, be sure that fluid levels have been topped off as required for the operation. When the engine is ready for starting, ensure that the engine 6i1 pump is (was) primed properly and is in a "ready to start" condition with all engine oil galleys having been charged with oil. WARNING DO NOT RACE THE ENGINE UPON INITIAL STARTUP. MAINTAIN ENGINE IDLE TO BUILD OIL PRESSURE. USE OF A MECHANICAL PRESSURE GAUGE WILL ENSURE THAT OIL FLOW HAS DEVELOPED ON THE PUMP'S PRESSURE SIDE. A DEFECTIVE GAUGE OR LIGHT IN THE INSTRUMENT PANEL WILL NOT VERIFY PRESSURE HAS BEEN OBTAINED. SEVERE INTERNAL ENGINE DAMAGE WILL RESULT IF PRESSURE IS NOT OBSERVED AND STEADILY MAINTAINED. Allow a warm up period, which brings the engine to normal operating temperature. Check for leaks around the gasket joints of the head, front cover, and associated component parts. The vehicle should be road tested within normal guidelines to raise the engine to operating temperature and verify the repair is sound. Shut down the engine, allow for a cool-down and drain-back period to enable fluids to return to levels. Check fluid levels using owner guide recommendations (dipstick, sight gages, etc.). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair REMOVAL 1. Remove the engine cooling fan and fan shroud. 2. Remove the drive belt. 3. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 4. Remove the drain plug and drain the engine oil. 5. Lower the vehicle 6. Remove the crankshaft pulley bolt. 7. Use (A) Crankshaft Damper Remover to remove the (B) crankshaft pulley. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 3012 8. Use (A) Front Cover Seal Remover to remove the (B) front cover seal. INSTALLATION 1. Lubricate the (A) engine front cover and (B) front oil seal inner lip. ^ Use engine oil meeting Ford specification WSE-M2C908-A1. 2. Use the (A) Crankshaft Seal Replacer/Aligner to install the (B) front oil seal into the (C) engine front cover. 3. Apply silicone to the woodruff key slot on the crankshaft pulley. ^ Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6. NOTE: The crankshaft pulley must be installed within four minutes after applying silicone. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 3013 4. Use Crankshaft Damper Replacer to install the crankshaft pulley. 5. Loosely install the crankshaft pulley bolt. 6. Tighten the crankshaft pulley bolt. NOTE: Make sure to tighten the crankshaft pulley bolt in four steps. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 3014 7. Loosen the crankshaft pulley bolt. 8. Tighten the crankshaft pulley bolt. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 3015 9. Tighten the crankshaft pulley bolt. 10. Raise and support the vehicle. 11. Install drain plug. 12. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. 13. Fill engine with engine oil meeting Ford specification WSE-M2C903-A1. 14. Install the drive belt. 15. Install the engine cooling fan and the fan shroud. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair Valve Guide Seal: Service and Repair REMOVAL 1. Remove the valve springs. 2. Remove the valve stem seals. INSTALLATION 1. Use (A) Valve Stem Seal Replacer to install the (B) valve stem seals. NOTE: Valve stem seal must be bottomed on valve seat. Ensure that garter spring is present in the valve stem seal. 2. Install the valve springs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Specifications Oil Pressure Switch (For Fuel Pump): Specifications Oil Pressure Switch 12-16 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Specifications > Page 3023 Oil Pressure Switch (For Fuel Pump): Testing and Inspection To avoid potential misdiagnosis and the unnecessary replacement of components, it is recommended that diagnosis and testing begin with Diagnostic Routines (Diagnosis by Symptom) at the Powertrain Management level. The Diagnostic Routines will lead the technician through the logical and methodical testing of a "specific" subsystem and it's related wiring and components. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Specifications > Page 3024 Oil Pressure Switch (For Fuel Pump): Service and Repair REMOVAL 1. Disconnect the oil pressure switch electrical connector. 2. Remove the oil pressure switch from the oil filter adapter. INSTALLATION 1. To install, reverse the removal procedure. 2. Check the oil level and fill to specification with Ford Premium SAE 1OW-30 Motor Oil XO-1OW-30-BSP, DSP, QSP or equivalent meeting Ford specification ESE-M2C153-E. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications TORQUE SPECIFICATIONS Camshaft Sprocket Bolt ........................................................................................................................................................ 110-130 Nm (81-95 Ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications > Page 3029 Camshaft Gear/Sprocket: Testing and Inspection WARNING: TO AVOID THE POSSIBILITY OF PERSONAL INJURY OR DAMAGE TO THE VEHICLE, DO NOT OPERATE THE ENGINE WITH THE HOOD OPEN UNTIL THE FAN BLADE HAS FIRST BEEN EXAMINED FOR POSSIBLE CRACKS AND SEPARATION. NOTE: Specifications show the expected minimum or maximum condition. If a component fails to meet the specifications, it is necessary to replace or refinish. If the component can be refinished, wear limits are provided as an aid to making a decision. Any component that fails to meet specifications and cannot be refinished must be replaced. PROCEDURE 1. Inspect the chain and the sprockets. 2. Replace as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Removal Timing Chain: Service and Repair Removal 1. Remove the engine front cover. 2. Remove the (A) crankshaft sensor ring from the (B) crankshaft. 3. Rotate the crankshaft until both camshaft keyways are 90° from the cam cover surface. Make sure the copper links line up with the dots on the camshaft sprockets. 4. Install the (A) Cam Positioning Tool and the Camshaft Positioning Tool Adapters on the (B) camshaft. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Removal > Page 3034 5. Remove the (A) LH timing chain tensioner bolts and the (B) LH timing chain tensioner. 6. Remove the (A) RH timing chain tensioner bolts and the (B) RH timing chain tensioner. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Removal > Page 3035 7. Remove the LH and RH timing chain tensioner guides from the dowel pins. 8. Remove the RH and LH timing chains and crankshaft sprockets. a. Lift RH timing chain off of the camshaft sprocket and slide the timing chain and crankshaft sprocket off of the crankshaft. b. Lift the LH timing chain off the camshaft sprocket and slide the timing chain and the crankshaft sprocket off of the crankshaft. CAUTION: At no time, when the timing chains are removed and the cylinder heads are installed may the crankshaft or camshaft be rotated. Severe piston and valve damage will occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Removal > Page 3036 9. Remove the chain guides. a. Remove the LH bolts. b. Remove the LH timing chain guide. c. Remove the RH bolts. d. Remove the RH timing chain guide. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Removal > Page 3037 Timing Chain: Service and Repair Installation CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result. 1. Compress the timing chain tensioners. a. Release the lock assembly on the timing chain tensioners. b. Compress the timing chain tensioners. 2. Install the retaining pins. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Removal > Page 3038 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Removal > Page 3039 3. Check the following components for part number orientation. 4. Install the timing chain guides. a. Position LH timing chain guide. b. Install and torque the LH timing chain guide bolts. c. Position the RH timing chain guide. d. Install and torque the RH timing chain guide bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Removal > Page 3040 5. Install the timing chain and crankshaft sprockets. a. Slide the (A) crankshaft sprocket onto the (B) crankshaft, aligning the copper link on the timing chain with the dot on the crankshaft sprocket. b. Position the timing chain over the camshaft sprocket, aligning the copper link with the dot on the camshaft sprocket. 6. Make sure that the (A) copper marks on the timing chain are lined up with the corresponding dots on the crankshaft and camshaft sprockets. 7. Make sure that the (A) camshaft sprocket keyway is 90° from the (B) cam cover mounting surface. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Removal > Page 3041 Fig. 26 Crankshaft Sprocket Position 8. Make sure that the (A) RH timing chain sprocket is on the front of the (B) LH timing chain sprocket with the hubs facing each other. 9. Position the LH and RH timing chain tensioner guides on the dowel pins. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Removal > Page 3042 10. Position the RH timing chain tensioner and install the timing chain tensioner bolts. 11. Position the LH timing chain tensioner and install the timing chain tensioner bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Removal > Page 3043 12. Remove both the RH and LH retaining pins from the timing chain tensioners. 13. Remove (A) Cam Positioning Tool and the Camshaft Positioning Tool Adapters on the (B) camshaft. 14. Install the (A) crankshaft sensor ring on the (B) crankshaft. 15. Install the engine front cover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Guide > Component Information > Specifications Timing Chain Guide: Specifications TORQUE SPECIFICATIONS Timing Chain Guide Bolts ...................................................................................................................................................... 8-12 Nm (71-107 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications Timing Chain Tensioner: Specifications TORQUE SPECIFICATIONS Timing Chain Tensioner Bolts ................................................................................................................................................ 20-30 Nm (14.7-22 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3053 TORQUE SPECIFICATIONS Tighten the engine front cover fasteners in two stages in the sequence shown. ^ Stage 1: Tighten fasteners 1-5 to 20-30 Nm (15-22 ft. lbs.). ^ Stage 2: Tighten fasteners 6-15 to 40-55 Nm (30-41 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3054 Timing Cover: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove both cam covers. 3. Remove the radiator. 4. Remove the water pump. 5. Disconnect the following electrical connections: ^ LH ignition coil connector (A). ^ Camshaft Position Sensor (CMP) electrical connector (B). ^ Radio capacitor electrical connector (C). 6. Disconnect the following electrical connections: ^ RH ignition coil electrical connector (A). ^ Radio capacitor electrical connector (B). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3055 7. Remove the ignition coils and ignition coil mounting brackets. 1. Remove the RH ignition coil and bracket bolts. 2. Remove the RH ignition coil and bracket. 3. Remove the LH ignition coil and bracket bolt. 4. Remove the LH ignition coil and bracket nuts. 5. Remove the LH ignition coil and bracket. 8. Raise and support the vehicle. 9. Remove the top power steering pump bolts. 10. Remove the lower power steering pump bolts and position the power steering pump aside. 11. Disconnect the Crankshaft Position (CKP) sensor electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3056 12. Remove the (A) CKP sensor bolt and the (B.) CKP sensor. 13. Remove the drain plug and drain the engine oil 14. Remove the front oil pan bolts. 15. Lower the vehicle. 16. Remove the front oil seal. 17. Remove the (A) CMP sensor bolt and the (B) CMP sensor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3057 18. Remove the (A) belt idler pulley bolt and the (B) belt idler pulley. 19. Remove accessory drive belt tensioner. 1. Remove the bolts. 2. Remove tensioner. 20. Remove the eight engine front cover bolts and seven engine front cover stud bolts. 21. Remove the engine front cover from the front cover to cylinder block dowel. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3058 1. Apply silicone along the head to block surface and the oil pan to block surface. ^ Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford Specification WSE-M4G323-A6. NOTE: The engine front cover must be installed within four minutes after applying silicone. 2. Install the engine front cover on the front cover to cylinder block dowel. 3. Loosely install the engine front cover bolts and stud bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3059 4. Tighten the engine front cover bolts and stud bolts in the sequence shown. NOTE: Make sure to tighten the engine front cover bolts and stud bolts in two steps. 5. Tighten front cover bolts and stud bolts in sequence shown. 6. Position the (A) belt idler pulley and install the (B) belt idler pulley bolt. 7. Install the accessory drive belt tensioner. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3060 1. Position the accessory drive belt tensioner. 2. Install bolts. 8. Position the (A) CMP sensor and install the (B) CMP sensor bolt. 9. Install a new engine front cover front oil seal. 10. Raise and support the vehicle. 11. Loosely install the front oil pan bolts. 12. Tighten the front oil pan bolts in the sequence shown. NOTE: Make sure to tighten the front oil pan bolts in two steps. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3061 13. Tighten the front oil pan bolts in the sequence shown. 14. Position the (B) CKP sensor and install the (A) CKP bolt. 15. Connect the CKP sensor electrical connector. 16. Install the power steering pump. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3062 1. Position the power steering pump. 2. Install the lower power steering bolts. 17. Install the top power steering bolts. 18. Install oil pan drain plug. 19. Lower the vehicle. 20. Install the ignition coils and brackets. 1. Position LH ignition coil and bracket. 2. Install LH ignition coil and bracket nuts. 3. Install LH ignition coil and bracket bolt. 4. Position RH ignition coil and bracket. 5. Install RH ignition coil and bracket bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3063 21. Connect the following electrical connections: ^ RH ignition coil electrical connector (A). ^ Radio capacitor electrical connector (B). 22. Connect the following electrical connections: ^ LH ignition coil connector (A). ^ CMP electrical connector (B). ^ Radio capacitor electrical connector (C). 23. Install the cam covers. 24. Install the radiator. 25. Connect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 26. Fill the engine with oil. ^ Use engine oil meeting Ford specification WSE-M2C903-A 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications Fuel Pressure Test Port: Specifications Pressure Relief Valve 7.75 Nm Pressure Relief Valve Cap 0.6 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 3069 Fuel Pressure Test Port: Locations Typical Location The fuel pressure test point/port is a Schrader fitting, located in the fuel rail. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 3070 Fuel Pressure Test Port: Service Precautions WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited, resulting in possible injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. - Before repairing or disconnecting any of the fuel lines or fuel system components, the fuel system fuel pressure release procedure must be performed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 3071 Fuel Pressure Test Port: Description and Operation Typical Location Purpose There is a pressure test point with a Schrader fitting in the fuel rail, which is used for fuel pressure release and to measure the injector supply pressure for service and diagnostic work. NOTE:Before servicing or testing the fuel system, read CAUTION, WARNING, and HANDLING information. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 3072 Fuel Pressure Test Port: Service and Repair REMOVAL 1. Perform Fuel Pressure Release Procedure 2. Remove the fuel pressure relief valve. INSTALLATION To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > System Diagnosis Air/Fuel Mixture: Testing and Inspection To avoid potential misdiagnosis and the unnecessary replacement of components, it is recommended that diagnosis and testing begin with Diagnostic Routines (Diagnosis by Symptom) at the Powertrain Management level. The Diagnostic Routines will lead the technician through the logical and methodical testing of a "specific" subsystem and it's related wiring and components. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > System Diagnosis > Page 3076 Air/Fuel Mixture: Adjustments Air Fuel Ratio is NOT adjustable. If a problem exists, or is suspected, go to the Diagnostic Charts: See Powertrain Management Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Idle Speed (Non-Adjustable) Idle Speed (Non-Adjustable) Base Idle Speed (Standard Trans/Hot) 750 +/- 25 rpm Base Idle Speed (Automatic Trans/Hot) 824 +/- 25 rpm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 3080 Idle Speed: Adjustments Engine Idle RPM is controlled by the PCM and is NOT adjustable. If a problem exists, or is suspected, see: Powertrain Management / Symptom Charts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Tube Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Outlet Tube REMOVAL 1. Remove the accelerator control splash shield. 1 Remove the accelerator control splash shield bolts. 2 Remove the accelerator control splash shield. 2. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 3. Disconnect the (A) positive crankcase ventilation hose and the (B) idle air control valve inlet tube. 4. Loosen the two air cleaner outlet tube hose clamp screws and remove the air cleaner outlet tube. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Tube > Page 3086 To install, reverse the removal procedure. CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Tube > Page 3087 Air Cleaner Fresh Air Duct/Hose: Service and Repair Removal and Installation REMOVAL 1. Open the (A) air cleaner clamp and set the (B) outlet engine air cleaner aside. 2. Lift the (B) open end of the (A) inlet engine air cleaner until free of the (C) engine air cleaner support insulators. CAUTION: The inlet engine air cleaner should be removed as an assembly. Do not separate the air cleaner from the fender inlet tube during removal or installation. 3. Pull the inlet engine air cleaner away from the inner fender. INSTALLATION CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. NOTE: The inlet engine air cleaner has an alignment tab which fits into a slot on the outlet engine air cleaner. This ensures a good seal and keeps unmetered air from entering the engine. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL 1. Open the (A) air cleaner clamp and set the (B) outlet engine air cleaner aside. 2. Remove the (A) air cleaner element from the (B) open end of the inlet engine air cleaner. INSTALLATION 1. Install the air cleaner element. NOTE: The inlet engine air cleaner has an alignment tab which fits into a slot on the outlet engine air cleaner. This ensures a good seal and keeps unmetered air from entering the engine. CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. 2. Position the engine air cleaner aligning the alignment tab. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 3091 3. Close the air cleaner clamp. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Locations Fuel Pressure Release: Locations Fuel Pressure Port (Typical) A fuel system service port is provided on the fuel rail. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Locations > Page 3096 Fuel Pressure Release: Service Precautions WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited, resulting in possible injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. - Before repairing or disconnecting any of the fuel lines or fuel system components, the fuel system fuel pressure release procedure must be performed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Locations > Page 3097 Fuel Pressure Release: Service and Repair Fuel Pressure Port (Typical) 1. Remove the schrader valve cap and attach EFI/CFI Fuel Pressure Gauge. 2. Open the manual valve on EFI/CFI Fuel Pressure Gauge and Perform Fuel Pressure Release. NOTE: Open manual value slowly to relieve system pressure. - This will drain some fuel out of the system. - Place fuel in suitable a container. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications The RH (Passenger's) side ................................................................................................................. ................................................ Cylinders 1, 2, 3, and 4 The LH (Driver's side) .......................................................................................................................... ............................................. Cylinders 5, 6, 7 and 8 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 3101 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 3102 Firing Order 1-3-7-2-6-5-4-8 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Firing Order Firing Order: 1-3-7-2-6-5-4-8 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Locations Timing Marks and Indicators: Locations The timing marks are located on the crankshaft pulley/damper. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Secondary Suppression Resistor, Ignition > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 962523 > Dec > 96 > Spark Plug Wires - MIL ON/DTCs P0300 Through P0308 Set Spark Plug: Customer Interest Spark Plug Wires - MIL ON/DTCs P0300 Through P0308 Set Article No. 96-25-23 12/02/96 ^ RUNS ROUGH - MALFUNCTION INDICATOR LAMP (MIL) ON-DIAGNOSTIC TROUBLE CODES (DTCS) P0300 THROUGH P0308 STORED IN MEMORY - VEHICLES BUILT THROUGH 10/14/96 WITH 4.6L ENGINE ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ON - RUNS ROUGH - DIAGNOSTIC TROUBLE CODES (DTCS) P0300 THROUGH P0308 STORED IN MEMORY - VEHICLES BUILT THROUGH 10/14/96 WITH 4.6L ENGINE LIGHT TRUCK: 1997 ECONOLINE, EXPEDITION, F-150 ISSUE: The Malfunction Indicator Lamp (MIL) may illuminate and Diagnostic Trouble Codes (DTCs) P0300 through P0308 may be stored in memory and/or the engine may run rough. This may be caused by water intrusion into the spark plug well causing the spark to travel directly to ground instead of through the spark plug, resulting in a misfire. ACTION: Inspect the spark plugs for signs of moisture and replace the spark plugs and spark plug wires. Apply dielectric compound on all of the spark plug wire boots. The new spark plug wires and the dielectric compound should reduce the possibility of misfire if water intrusion into the spark plug well occurs. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect and remove any water that may be sitting in the spark plug wells by blowing out the water using compressed air. 2. Inspect the spark plugs for signs of "tracking." If "tracking" is present, there may be a fine, broken "pencil" line on the blue rings only and/or a thick smudgy series of continuous lines depending on how long the vehicle was operated while misfiring. These lines may feel like a crack if the fingernail is rubbed across the lines. Refer to Figure 1. 3. If "tracking" is found, replace all eight (8) of the spark plugs and torque the new Spark Plugs (AWSF-32-PP) to 16-20 N.m (12-15 lb-ft). 4. Replace all eight (8) of the Spark Plug Wires with new wires (F6PZ-12259-HC). Be sure to apply Silicone Caliper Grease and Dielectric Compound (D7AZ-19A331-A) on the inside of all spark plug wire boots. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 962523 > Dec > 96 > Spark Plug Wires - MIL ON/DTCs P0300 Through P0308 Set > Page 3122 5. Position the spark plug wire boots 90 degrees to the crankshaft centerline with the spark plug wires facing outboard. The lip of the spark plug wire boot must be flush to the manifold. Refer to Figure 2. PART NUMBER PART NAME F6PZ-12259-HC Spark Plug Wires AWSF-32-PP Spark Plug D7AZ-19A331-A Silicone caliper Grease And Dielectric Compound OTHER APPLICABLE ARTICLES: 96-20-5 960923 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 962523 > Dec > 96 > Spark Plug Wires - MIL ON/DTCs P0300 Through P0308 Set > Page 3123 OPERATION DESCRIPTION TIME 962523A Replace Spark Plugs And 1.1 Hr. Wires DEALER CODING CONDITION BASIC PART NO. CODE 12286 48 OASIS CODES: 206000, 608400, 608500, 608600, 609000, 609400, 609500, 609600, 609800, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 962523 > Dec > 96 > Spark Plug Wires - MIL ON/DTCs P0300 Through P0308 Set Spark Plug: All Technical Service Bulletins Spark Plug Wires - MIL ON/DTCs P0300 Through P0308 Set Article No. 96-25-23 12/02/96 ^ RUNS ROUGH - MALFUNCTION INDICATOR LAMP (MIL) ON-DIAGNOSTIC TROUBLE CODES (DTCS) P0300 THROUGH P0308 STORED IN MEMORY - VEHICLES BUILT THROUGH 10/14/96 WITH 4.6L ENGINE ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ON - RUNS ROUGH - DIAGNOSTIC TROUBLE CODES (DTCS) P0300 THROUGH P0308 STORED IN MEMORY - VEHICLES BUILT THROUGH 10/14/96 WITH 4.6L ENGINE LIGHT TRUCK: 1997 ECONOLINE, EXPEDITION, F-150 ISSUE: The Malfunction Indicator Lamp (MIL) may illuminate and Diagnostic Trouble Codes (DTCs) P0300 through P0308 may be stored in memory and/or the engine may run rough. This may be caused by water intrusion into the spark plug well causing the spark to travel directly to ground instead of through the spark plug, resulting in a misfire. ACTION: Inspect the spark plugs for signs of moisture and replace the spark plugs and spark plug wires. Apply dielectric compound on all of the spark plug wire boots. The new spark plug wires and the dielectric compound should reduce the possibility of misfire if water intrusion into the spark plug well occurs. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect and remove any water that may be sitting in the spark plug wells by blowing out the water using compressed air. 2. Inspect the spark plugs for signs of "tracking." If "tracking" is present, there may be a fine, broken "pencil" line on the blue rings only and/or a thick smudgy series of continuous lines depending on how long the vehicle was operated while misfiring. These lines may feel like a crack if the fingernail is rubbed across the lines. Refer to Figure 1. 3. If "tracking" is found, replace all eight (8) of the spark plugs and torque the new Spark Plugs (AWSF-32-PP) to 16-20 N.m (12-15 lb-ft). 4. Replace all eight (8) of the Spark Plug Wires with new wires (F6PZ-12259-HC). Be sure to apply Silicone Caliper Grease and Dielectric Compound (D7AZ-19A331-A) on the inside of all spark plug wire boots. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 962523 > Dec > 96 > Spark Plug Wires - MIL ON/DTCs P0300 Through P0308 Set > Page 3129 5. Position the spark plug wire boots 90 degrees to the crankshaft centerline with the spark plug wires facing outboard. The lip of the spark plug wire boot must be flush to the manifold. Refer to Figure 2. PART NUMBER PART NAME F6PZ-12259-HC Spark Plug Wires AWSF-32-PP Spark Plug D7AZ-19A331-A Silicone caliper Grease And Dielectric Compound OTHER APPLICABLE ARTICLES: 96-20-5 960923 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 962523 > Dec > 96 > Spark Plug Wires - MIL ON/DTCs P0300 Through P0308 Set > Page 3130 OPERATION DESCRIPTION TIME 962523A Replace Spark Plugs And 1.1 Hr. Wires DEALER CODING CONDITION BASIC PART NO. CODE 12286 48 OASIS CODES: 206000, 608400, 608500, 608600, 609000, 609400, 609500, 609600, 609800, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Electrode Gap 1.32-1.42 mm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 3133 Spark Plug: Specifications Spark Plug 9-20 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3134 Spark Plug: Locations The Spark Plugs are located along the inboard sides of the cylinder heads, and outboard of the intake manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3135 Spark Plug: Application and ID RH Original Spark Plug ....................................................................................................................... ........................................................ AWSF32PG (a) LH Original Spark Plug ..................................... ............................................................................................................................................. AWSF32P (a) Replacement Spark Plug (Either Side) ......................................................................................................................................................... AWSF32PP (a) (a) If a spark plug is removed for examination, it must be reinstalled in the same cylinder. If a spark plug needs to be replaced, use only spark plugs with the base part number suffix "PP" as shown on the engine decal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3136 Spark Plug: Description and Operation Spark Plug Construction PURPOSE Ignites the combustion mixture. LOCATION Threaded into the cylinder head, at the combustion chamber. OPERATION The spark plug provides a path for the high current of the secondary circuit to flow to ground. The only paths for this current are through the ground electrode and center electrode across the spark gap. The spark produced when the current jumps the gap and ignites the air/fuel mixture in the cylinder. Spark Plug Heat Range CONSTRUCTION The temperature of the spark plug is determined by the length of the insulator and the size of the heatsink area. The longer the insulator is, the smaller the heatsink area will be and this will cause the spark plug to be hotter. - Change high voltage pulses to spark at gap which ignites fuel and air mixture. - Have a platinum enhanced active electrode for long life. FEATURES The active electrode is different for LH and RH spark plugs: - On the RH side (cylinders 1, 2, 3, and 4) are type AWSF-32PG. - On the LH side (cylinders 5, 6, 7 and 8) are type AWSF-32P. NOTE: The replacement spark plugs are AWSF-32PP; both electrodes are platinum enhanced so it can replace either a RH or LH spark plug. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3137 Spark Plug: Testing and Inspection CLEANING AND INSPECTION Spark Plugs Inspect the electrodes and outer surface. Refer to Spark Plug Inspection Chart. Replace spark plugs if they are worn or damaged. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3138 Spark Plug: Adjustments Gapping Spark Plug Check and set the spark plug electrode gap to: 1.32-1.41 mm (0.052-0.056 inch) using an appropriate gapping tool. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3139 Spark Plug: Service and Repair REMOVAL NOTE: - If an original spark plug is reused, make sure it is placed in the same cylinder it was taken from. Replacement spark plugs can be used in any cylinder. - Use compressed air to remove any debris from the spark plug well before removing the spark plugs. 1. With a twisting, pulling motion disconnect the spark plug wire from the spark plug. 2. Squeeze the (A) locking tabs and disconnect the (B) spark plug wire from the (C) ignition coil. 3. Remove the RH spark plugs. 4. Remove the LH spark plugs. 5. Inspect the spark plugs for: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3140 - Deposits bridging spark plug gap (A). - Wet black deposits (oil fouling) (B). - Dry black deposits (carbon fouling) (C). - Overheating (D). - Deposits fused on spark plug (E). Pre-ignition damage (F). - Normal spark plug (G). INSTALLATION NOTE: If an original spark plug is reused, make sure it is placed in the same cylinder it was taken from. Replacement spark plugs can be used in any cylinder. 1. Apply Silicone Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A to inside of spark plug wire boots. 2. Adjust the spark plug gap as required. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3141 3. Install the LH spark plugs. 4. Install the RH spark plugs. 5. Connect the spark plug wires. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart above. If one or more cylinders reads low, squirt approximately one tablespoon of clean engine oil meeting Ford specification ESE-M2C153-E on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Gauge Check Compression Check: Testing and Inspection Gauge Check 1. Make sure the oil in the crankcase is of the correct viscosity and at the proper level and that the battery is properly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as Compression Tester in No.1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, use the auxiliary starter switch to crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Gauge Check > Page 3147 Compression Check: Testing and Inspection Interpreting Compression Readings 1. If compression improves considerably, the piston rings are faulty. 2. If compression does not improve, the valves are sticking or seating improperly. 3. If two adjacent cylinders indicate low compression pressures and squirting oil on the piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil and/or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75 percent of the highest reading. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Gauge Check > Page 3148 Compression Check: Testing and Inspection Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart above. If one or more cylinders reads low, squirt approximately one tablespoon of clean engine oil meeting Ford specification ESE-M2C153-E on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Gauge Check > Page 3149 Compression Check: Testing and Inspection Cylinder Leakage Test When a cylinder produces a low reading, the use of Engine Cylinder Leak Detection/Air Pressurization Kit will be helpful in pinpointing the exact cause. The leakage detector is inserted in the spark plug hole, the piston is brought up to dead center on the compression stroke, and compressed air is admitted. Once the combustion chamber is pressurized, a special gauge included in the kit will read the percentage of leakage. Leakage exceeding 20 percent is excessive. While the air pressure is retained in the cylinder, listen for the hiss of escaping air. A leak at the intake valve will be heard in the throttle body. A leak at the exhaust valve can be heard at the tail pipe. Leakage past the piston rings will be audible at the positive crankcase ventilation (PCV) connection. If air is passing through a blown head gasket to an adjacent cylinder, the noise will be evident at the spark plug hole of the cylinder into which the air is leaking. Cracks in the cylinder block or gasket leakage into the cooling system may be detected by a stream of bubbles in the radiator. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Hydraulic lash adjusters provide automatic lash compensation. No adjustment is necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 3153 Valve Clearance: Adjustments Hydraulic lash adjusters provide automatic lash compensation. No adjustment is necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Drive Pulley, Water Pump > Component Information > Specifications Drive Pulley: Specifications DRIVE RATIO Pump Pulley Ratio ............................................................................................................................... ......................................................................... 1.3 TORQUE SPECIFICATIONS Water Pump Pulley Bolts ........................................................................................................................................................ 20-30 Nm (14.7-22 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement Technical Service Bulletin # 98B33 Date: 990401 Campaign - Coolant/Cylinder Head Replacement OWNER NOTIFICATION PROGRAM 98B33 Certain 1997 and 1998 Expedition, F-150 and 1998 Navigator vehicles equipped with 4.6L and 5.4L engines for inspection of coolant and, if necessary, replacement of engine cylinder heads ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Refund Codes ^ Attachment II ^ Labor Allowances ^ Parts Requirements ^ Attachment IIIA ^ A - Coolant Test Instructions ^ Attachment IIIB ^ B - Cylinder Head Replacement Instructions ^ Attachment IV ^ Copy of Lincoln Commitment Special Handling Procedure Letter ^ Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3167 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3168 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles on the enclosed list. PROMPTLY CORRECT ^ Affected vehicles on the enclosed list. ^ Other eligible vehicles which are brought to your dealership. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3169 DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with this special handling procedure. CLAIMS Enter claims using DWE. See ACESII Manual. To claim for the "Lincoln Commitment Special Handling", follow the instructions on Attachment IV. OWNER REFUNDS See ACESII Manual, Section 3 for submission procedures. For owner-paid repairs of cracked cylinder heads or damage directly related to cracked cylinder heads made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from servicing dealer), enter using DWE: RENTAL CARS If cylinder head replacement is necessary, Ford will pay for a loaner or rental vehicle except for fuel and insurance which will be at the owner's expense. Do not provide a rental vehicle while cylinder heads are on order. Rentals should be provided only while the vehicle is at the dealership for cylinder head replacement. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number of days vehicle was used in the Miscellaneous Expense area of the recall claim. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3170 COOLANT TESTER Coolant concentrate test kits will be sent at no charge 10 dealers with affected vehicles. Additional stock of testers is limited, but testers may be ordered from the Recall Hotline 1-800-325-5621. PARTS REQUIREMENTS Parts Ordering Information Cylinder head kits can be ordered by calling the Recall Hotline at 1-800-325-5621. The kits listed contain all parts necessary for cylinder head replacement except coolant, oil and oil filter: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3171 DEALER PRICE For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book CLAIMS PREPARATION Enter using DWE. Use code information shown below: ^ Program Code: 98B33 ^ Labor Operation: (see Labor Allowances) See the ACESII manual for detailed instructions. Attachment IIIA - A-Coolant Test Instructions SERVICE PROCEDURE 1. Open hood. 2. Remove coolant recovery bottle cap. 3. Run engine until normal operating temperature (thermostat open) is reached. 4. Insert supplied glycol tester (Thexton 106) into coolant recovery bottle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3172 5. Fill tester to level shown in Figure 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3173 ^ If five (5) or less discs float, refer to Figure 2, no service action is needed. Return vehicle to customer. ^ If all six (6) discs float, indicating "NOT SAFE" glycol condition, see Figure 2, call Recall Hotline at 1-800-325-5621 to order cylinder head kit. Perform cylinder head replacement, when kit arrives. Removal Removal 1. On air suspension equipped vehicles, turn air suspension switch, located in the RH kick panel area, to the OFF position. 2. Install memory saver, then disconnect battery negative cable. 3. Remove shield covering throttle body assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3174 4. Disconnect mass air flow (MAF) sensor electrical connector. Refer to Figure 1. 5. Disconnect intake air temperature (IAT) sensor electrical connector. Refer to Figure 1. 6. Remove air cleaner half and clean air tube as an assembly. See Figure 1. 7. Remove remaining half of air cleaner. 8. Disconnect accelerator cable, speed control cable and return spring from throttle body. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3175 9. Remove accelerator cable bracket from intake manifold, then unclip cables from clip on power steering reservoir bracket. See Figure 2. Position cable assembly aside. 10. On 4.6L engines, proceed as follows: ^ Disconnect vapor management valve (VMV) vacuum line at rear of throttle body adapter. Refer to Figure 3. ^ Disconnect vacuum tap on right side of throttle body adapter. Refer to Figure 3. ^ Disconnect PCV hose at rear of throttle body adapter. Refer to Figure 3. ^ Remove brake booster vacuum line retainer at EGR valve. Disconnect vacuum line at throttle body adapter. See Figure 3. Position line aside. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3176 ^ Disconnect vapor management valve (VMV) vacuum line. Refer to Figure 4. ^ Disconnect fuel pressure regulator vacuum line. Refer to Figure 4. ^ Disconnect EGR valve vacuum line. Refer to Figure 4. ^ Disconnect EVR solenoid vacuum line. See Figure 4. ^ Position vacuum harness away from engine. 11. On 5.4L engines, proceed as follows: ^ Remove power steering reservoir bracket retainers, then position reservoir assembly aside. See Figure 5. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3177 ^ Disconnect crankcase vent tube from left cam cover. Remove vent tube from vehicle. 12. Raise vehicle. 13. Disconnect EGR tube from exhaust manifold. 14. Disconnect oil pressure switch electrical connector. See Figure 6. 15. Disconnect crankshaft position (CKP) sensor electrical connector. See Figure 7. 16. On 4X2 models, disconnect A/C clutch electrical connector. 17. Drain coolant from radiator. NOTE: Do not remove right side cylinder block coolant drain plug. 18. Remove left side cylinder block coolant drain plug. Allow coolant to completely drain. 19. Install cylinder block coolant drain plug. Tighten plug to 16-24 Nm (12-17 lb-ft). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3178 20. Drain engine oil. Do not final tighten drain plug at this time, as it will be removed again. 21. Lower vehicle. NOTE: The best access to the A/C electrical connector is through the wheel well. 22. On 4X4 models, disconnect A/C clutch electrical connector. 23. Mark and disconnect DPFE transducer hoses from EGR tube. 24. Disconnect EGR tube from EGR valve, then remove EGR tube from vehicle. 25. On 4.6L engines, proceed as follows: ^ Remove power steering reservoir bracket retainers, then position reservoir assembly aside. See Figure 8. ^ Disconnect crankcase vent tube from left cam cover. Remove vent tube from vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3179 ^ Disconnect EVR solenoid electrical connector. Refer to Figure 9. ^ Disconnect Throttle Position (TP) sensor electrical connector. Refer to Figure 9. ^ Disconnect Idle Air Control (IAC) motor electrical connector. Refer to Figure 9. ^ Disconnect DPFE transducer electrical connector. See Figure 9. ^ Disconnect left side coil pack electrical connector. Refer to Figure 10. ^ Disconnect camshaft position (CMP) sensor electrical connector. Refer to Figure 10. ^ Disconnect left side radio interference suppressor electrical connector. See Figure 10. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3180 ^ Disconnect ignition wires from left side coil pack. ^ Remove left side coil pack from vehicle. ^ Unclip left side fuel charge harness from cam cover studs. Refer to Figure 11. ^ Unclip ignition wire separators from left cam cover studs. See Figure 11. ^ Disconnect ignition wires from left side spark plugs. Route ignition wires to front of engine. ^ Disconnect left side fuel injector electrical connectors. 26. On 5.4L engines, proceed as follows: ^ Disconnect Vapor Management Valve (VMV) vacuum line. Refer to Figure 12. ^ Disconnect fuel pressure regulator vacuum line. Refer to Figure 12. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3181 ^ Disconnect EGR valve vacuum line. Refer to Figure 12. ^ Disconnect EVR solenoid vacuum line. See Figure 12 ^ Disconnect vacuum tap on right side of throttle body adapter. Refer to Figure 13. ^ Position vacuum harness away from engine. ^ Disconnect VMV purge line at top of throttle body adapter. See Figure 13. ^ Disconnect brake booster vacuum line from throttle body adapter. ^ Remove brake booster vacuum line bracket from intake manifold. Position vacuum line assembly away from intake manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3182 ^ Disconnect Idle Air Control (IAC) motor electrical connector. See Figure 14. ^ Disconnect left side radio interference suppressor electrical connector. Refer to Figure 15. ^ Disconnect DPFE transducer electrical connector. Refer to Figure 15. ^ Disconnect EVR solenoid electrical connector. Refer to Figure 15. ^ Disconnect Throttle Position (TP) sensor electrical connector. Refer to Figure 15. ^ Disconnect Engine Coolant Temperature (ECT) sensor electrical connector. See Figure 15. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3183 ^ Disconnect camshaft position (CMP) sensor electrical connector. See Figure 16. ^ Disconnect ignition coil electrical connectors from left side of engine. Refer to Figure 17. ^ Disconnect fuel injector electrical connectors from left side of engine. See Figure 17. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3184 ^ Remove left side fuel charge harness from cam cover studs, then position harness away from cam cover. See Figure 18. ^ Remove left side ignition coils from vehicle. WARNING DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. WARNING FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. 27. Relieve fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on EFI/CFI fuel pressure gauge. ^ Remove fuel pressure gauge and reinstall schrader valve cap. 28. Disconnect fuel lines from fuel manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3185 29. Remove junction block splash shield. See Figure 19. 30. Disconnect positive leads from starter relay. Refer to Figure 20. 31. Unclip two (2) mega-fuses from bracket. Refer to Figure 20. 32. Disconnect two (2) 42-pin bulkhead electrical connectors. Refer to Figure 20. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3186 33. Remove both bulkhead electrical connector halves from bracket. See Figure 20. 34. Disconnect 16-pin electrical connector. Refer to Figure 21. 35. Disconnect single-pin electrical connector. Refer to Figure 21. 36. Remove junction block bracket. See Figure 21. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3187 37. Remove heater supply hose from vehicle. Refer to Figure 22. 38. Disconnect heater return hose from heater core fitting. Then position hose away from right cam cover. Refer to Figure 22. 39. Remove ground strap to bulkhead retaining bolt, then unwrap ground strap from fuel manifold. See Figure 22. 40. Remove PCV valve and line from vehicle. 41. On 4.6L engines, proceed as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3188 ^ Disconnect right side coil pack electrical connector. Refer to Figure 23. ^ Disconnect right side radio interference suppressor electrical connector. Refer to Figure 23. ^ Disconnect ignition wires from right side coil pack. See Figure 23. ^ Remove right side coil pack from vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3189 ^ Unclip right side fuel charge harness from cam cover studs. Refer to Figure 24. ^ Unclip ignition wire separators from right cam cover studs. See Figure 24. ^ Disconnect ignition wires from right side spark plugs. Route ignition wires to front of engine. ^ Disconnect right side fuel injector electrical connectors. ^ Disconnect Engine Coolant Temperature (ECT) sensor electrical connector. Refer to Figure 25. ^ Disconnect water temperature sender electrical connector. Refer to Figure 25. ^ Remove tie strap retaining alternator wiring harness to fuel manifold. See Figure 25. 42. On 5.4L engines, proceed as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3190 ^ Disconnect right side radio interference suppressor. See Figure 26. ^ Disconnect ignition coil electrical connectors from right side of engine. Refer to Figure 27. ^ Disconnect fuel injector electrical connectors from right side of engine. See Figure 27. ^ Remove right side fuel charge harness from cam cover studs, then position harness away from cam cover. ^ Remove right side ignition coils from vehicle. ^ Remove tie strap retaining alternator wiring harness to fuel manifold. 43. Disconnect upper radiator hose from thermostat housing. 44. Remove drive belt. 45. Remove alternator and mounting bracket as an assembly. The ignition wires and the alternator wiring harness will also be removed with the alternator assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3191 46. Disconnect cylinder head temperature (CHT) sensor electrical connector. Refer to Figure 28. 47. Disconnect tuning valve electrical connector. See Figure 28. 48. Remove the intake manifold retaining bolts. See Figure 29. 49. Remove intake manifold from vehicle. 50. Remove and discard intake manifold gaskets. NOTE: On 5.4L engine, cam cover bolts cannot be separated from cam cover. NOTE: Be careful not to damage cam cover gaskets, as they will be reused. Remove both camshaft covers. 51. Remove both camshaft covers. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3192 52. Disconnect heater return hose from coolant tube, then remove heater hose from vehicle. Refer to Figure 30. 53. Remove retainers securing routing bracket to rear of right-hand cylinder head, then remove routing bracket and ground strap. Refer to Figure 30. 54. Remove coolant tube retainers securing coolant tube to rear of right hand cylinder head, then remove coolant tube. See Figure 30. 55. Remove jack handle from radiator air deflector. 56. Remove air deflector on top of radiator. 57. Disconnect coolant recovery hose from radiator. 58. Using Fan Clutch Holding Tool T84T-6312-C and Fan Clutch Wrench T93T-6312-B, remove cooling fan and clutch assembly. 59. Remove cooling fan shroud. 60. On automatic transmission models, disconnect transmission lines from radiator. 61. Disconnect lower radiator hose from radiator. 62. Remove radiator support brackets, then the radiator. 63. Remove water pump pulley, then the water pump. 64. On 4.6L and 5.4L Windsor engines, proceed as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3193 ^ Remove two (2) upper power steering pump retaining bolts. Refer to Figure 31. ^ Raise vehicle. ^ Remove one (1) lower power steering pump retaining bolt, then position power steering pump away from front engine cover. See Figure 31. 65. On Romeo engines, proceed as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3194 ^ Remove two (2) upper power steering pump retaining bolts. See Figure 32. ^ Raise vehicle. NOTE: One of the following bolts cannot be completely removed from the power steering pump due to clearance with the power steering line. ^ Remove two (2) lower power steering pump retaining bolts, then position power steering pump away from front engine cover. See Figure 33. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3195 66. Remove four (4) front oil pan bolts. See Figure 34. 67. Lower vehicle. 68. Using Crankshaft Damper Remover T58P-6316-D, remove crankshaft pulley. 69. Using Front Cover Seal Remover T74P-6700-A, remove engine front cover oil seal. 70. Remove idler pulley from right side of engine front cover. This pulley blocks a front cover bolt. 71. Remove engine front cover retainers. See Figure 35. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3196 72. Remove engine front cover from engine. See Figure 36. 73. Remove crankshaft sensor ring. 74. Using Crankshaft Holding Tool T93P-6303-A, rotate crankshaft until crankshaft keyway points to the 12 o'clock position. See Figure 37. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3197 75. Install Camshaft Holding Tool T96T-6256-B, on each camshaft. See Figure 38 for holding tool placement. 76. Remove both timing chain tensioners. See Figure 39. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3198 77. Remove both timing chain tensioner guides. See Figure 40. 78. Lift right-hand timing chain off camshaft sprocket, then slide timing chain and crankshaft sprocket off crankshaft. Refer to Figure 41. 79. Lift left-hand timing chain off camshaft sprocket, then slide timing chain and crankshaft sprocket off crankshaft. See Figure 41. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3199 80. Remove both timing chain guides. See Figures 42 and 43. NOTE: Removal of this wheel opening molding screw is necessary to access all screws for the fender splash shield. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3200 81. On 4X4 models, remove one (1) screw shown in Figure 44, from both wheel opening moldings. 82. Remove both front fender splash shields. See Figure 45. 83. Raise vehicle. 84. Disconnect exhaust Y-pipe from exhaust manifolds. 85. Slightly lower vehicle. Exhaust manifold retainers will be accessed through the wheel well opening. 86. Remove left side exhaust manifold and gasket. Retain gasket for reuse. Replace gasket if damaged. 87. Loosen engine oil indicator tube; then turn tube away from cylinder head. Removal of indicator tube is not necessary. 88. Remove right side exhaust manifold and gasket. Retain gasket for reuse. Replace gasket if damaged. 89. Remove retainer securing transmission indicator tube to right cylinder head if equipped. NOTE: Cylinder head bolts that are under the camshaft holding tools cannot be completely removed from the head due to clearance with the holding tool. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3201 Completely loosen these bolts. 90. Remove both cylinder heads. See Figure 46. Discard all cylinder head bolts. 91. Remove and discard both cylinder head gaskets. 92. On Romeo engines, proceed as follows: ^ Remove spark plugs from right cylinder head. ^ Remove camshaft sprocket from right side camshaft. ^ Remove Camshaft Holding Tool from right side camshaft. ^ Install camshaft sprocket on new right side camshaft. Do not final tighten retaining bolt at this time. ^ Remove spark plugs from left cylinder head. ^ Remove camshaft sprocket from left side camshaft. ^ Remove Camshaft Holding Tool from left side camshaft. ^ Install camshaft sprocket on new left side camshaft. Do not final tighten retaining bolt at this time. ^ Remove power steering reservoir bracket and CHT sensor from left cylinder head. 93. On 4.6L and 5.4L Windsor engines, proceed as follows: ^ Remove Camshaft Holding Tools from both camshafts. ^ Remove power steering reservoir bracket and Cylinder Head Temperature sensor from left cylinder head. ^ Remove all eight (8) spark plugs from cylinder heads. 94. Clean the following gasket surfaces: ^ Cylinder block to cylinder head. ^ Engine front cover. ^ Water pump. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3202 ^ Intake manifold. ^ Both cam covers. Installation 1. On all cylinder heads, install one (1) pipe plug into the rear of each cylinder head in locations shown in Figure 47. 2. On 4.6L Romeo engines, install one (1) pipe plug into the front of each cylinder head in locations shown in Figure 48. 3. Install CHT sensor to left cylinder head. Tighten sensor to 24-28 Nm (17-20 lb-ft). 4. Install power steering bracket to left cylinder head. 5. Install all spark plugs (both sides). Tighten plugs to 9-20 Nm (81-178 lb-in). 6. Install right cylinder head gasket. 7. Install right cylinder head. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3203 8. Tighten right cylinder head bolts in sequence shown in Figure 49 in the following three (3) stages: ^ Stage 1: 37-43 Nm (27-32 lb-ft). ^ Stage 2: Rotate 85-95 degrees. ^ Stage 3: Rotate 85-95 degrees. 9. Lubricate all camshaft journals. 10. Install left cylinder head gasket. 11. Install left cylinder head. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3204 12. Tighten left cylinder head bolts in sequence shown in Figure 50 in the following three (3) stages: ^ Stage 1: 37-43 Nm (27-32 lb-ft). ^ Stage 2: Rotate 85-95 degrees. ^ Stage 3: Rotate 85-95 degrees. 13. Lubricate all camshaft journals. 14. Raise vehicle. 15. Install transmission indicator tube retainer to right cylinder head if equipped. Tighten retainer to 18-23 Nm (14-16 lb-ft). 16. Install right side exhaust manifold gasket. NOTE: Due to clearance, the exhaust system Y-pipe mounting flange cannot be positioned on the exhaust manifold outlet after the exhaust manifold is installed on the cylinder head. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3205 17. Install right side exhaust manifold and gasket. Align exhaust system Y-pipe mounting flange with the studs in the exhaust manifold outlet before completely installing the exhaust manifold on the cylinder block. Tighten right side exhaust manifold retainers in sequence shown in Figure 51 to 18-22 Nm (13-16 lb-ft). 18. Position engine oil indicator tube in installed position. 19. Install left side exhaust manifold and gasket. Tighten retainers in sequence shown in Figure 52 to 18-22 Nm (13-16 lb-ft). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3206 20. Remove oil pan drain plug. Completely drain any fluid (oil, coolant) from oil pan. Reinstall drain plug, tightening to 11-16 Nm (98-143 lb-in). 21. Replace oil filter. 22. Install exhaust system Y-pipe to exhaust manifolds. Tighten retainers to 34-46 Nm (25-34 lb-ft). 23. Lower vehicle. 24. Install both fender splash shields. Tighten retainers to 10-13 Nm (89-115 lb-in). 25. On 4X4 models, install one screw removed from both wheel opening moldings. 26. On Romeo engines, proceed as follows: ^ Using socket on camshaft sprocket bolt, rotate left camshaft until timing mark is in 12 o'clock position. Refer to Figure 53. ^ Using socket on camshaft sprocket bolt, rotate right camshaft until timing mark is in 11 o'clock position. Refer to Figure 53. 27. On 4.6L and 5.4L Windsor engines, proceed as follows: ^ Using Camshaft Positioning Tool T96T-6256-AR, rotate left camshaft until timing mark is in 12 o'clock position. Refer to Figure 53. ^ Using Camshaft Positioning Tool T96T-6256-AR, rotate right camshaft until timing mark is in 11 o'clock position. See Figure 53. ^ Install Camshaft Holding Tool T96T-6256-B on each camshaft. 28. On Romeo engines, tighten both camshaft sprocket bolts to 110-130 Nm (81-95 lb-ft). CAUTION Rotate the crankshaft counterclockwise only. Do not rotate past position shown or severe piston and/or valve damage can occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3207 29. Rotate crankshaft using Crankshaft Holding Tool T93P-6303-A. See Figure 54. Fully install holding tool. This will position crankshaft keyway to about 10:30 position. 30. Remove Crankshaft Holding Tool. 31. Compress timing chain tensioner plunger as follows: CAUTION Do not compress the ratchet assembly. This will damage the ratchet assembly. CAUTION Use protective vocers over jaws of vise to prevent damage to tensioner. ^ Compress tensioner plunger using edge of vise. See Figure 55. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3208 ^ Using small screwdriver or pick, push back and hold ratchet mechanism. See Figure 56. ^ While holding ratchet mechanism, push ratchet arm back into tensioner housing. See Figure 57. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3209 ^ Install paper clip into hole in tensioner housing. This will hold ratchet assembly and plunger in during installation. See Figure 58. ^ Remove tensioner from vise. ^ Repeat procedure for second tensioner. 32. If copper links are not visible, mark one (1) link on each end of the timing chain. One link will be an inside link. Use these marks as timing marks. See Figure 59. Repeal this step for other timing chain, if necessary. 33. Install right side timing chain guide. Tighten retainers to 8-12 Nm (71-106 lb-in). 34. Install left side timing chain guide. Tighten retainers to 8-12 Nm (71-106 lb-in). 35. Install timing chains and sprockets as follows: ^ Position left side crankshaft sprocket in left side timing chain. Make sure crankshaft sprocket hub is facing outward. Align mark on timing chain with corresponding dot on crankshaft sprocket. ^ Slide left side sprocket and chain on crankshaft. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3210 ^ Position left side timing chain over camshaft sprocket, aligning timing mark on chain with dot on camshaft sprocket. If necessary, loosen camshaft holding tool and adjust camshaft sprocket to obtain timing mark alignment. Tighten camshaft holding tool after timing marks are aligned. ^ Position right side crankshaft sprocket in right side timing chain. Make sure crankshaft sprocket hub is facing inward. Align mark on timing chain with corresponding dot on crankshaft sprocket. ^ Slide right side sprocket and chain on crankshaft. ^ Position right side timing chain over camshaft sprocket, aligning timing mark on chain with dot on camshaft sprocket. If necessary, loosen camshaft holding tool and adjust camshaft sprocket to obtain timing mark alignment. Tighten camshaft holding tool after timing marks are aligned. ^ Make sure marks on timing chain are lined up with corresponding dots on crankshaft and camshaft sprockets. See Figure 60. ^ Make sure right side crankshaft sprocket is in front of left side crankshaft sprocket with hubs facing each other. See Figure 61. 36. Install right and left timing chain tensioner guides. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3211 37. Install right and left timing chain tensioners. Tighten retainers to 20-30 Nm (15-20 lb-ft). 38. Remove paper clips from both timing chain tensioners. 39. Remove both camshaft holding tools. 40. Install crankshaft sensor ring. 41. Install engine front cover as follows: NOTE: The engine front cover must be installed within four (4) minutes after applying silicone. Apply Silicone Gasket and Sealant F6AZ-1 9562-AA or equivalent, along head to block surface and oil pan to block surface. See Figure 62. ^ Using new gasket, install engine front cover. Align cover with cylinder block dowel. ^ Loosely install engine front cover bolts and stud bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3212 ^ Tighten first five (5) engine front cover bolts in sequence shown in Figure 63, to 20-30 Nm (15-22 lb-ft). ^ Tighten remaining ten (10) engine front cover bolts in sequence shown in Figure 64. On Romeo engines, tighten bolts to 20-30 Nm (15-22 lb-ft). On 4.6L and 5.4L Windsor engines, tighten bolts to 40-55 Nm (29-40 lb-ft). 42. Install right side idler pulley. Tighten retainer to 20-30 Nm (15-22 lb-ft). 43. Using clean engine oil, lubricate engine front cover oil seal inner lip. 44. Using Crankshaft Seal Replacer/Aligner T88T-6701-A, install front cover oil seal. 45. Install crankshaft pulley as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3213 NOTE: The crankshaft pulley must be installed within four (4) minutes after applying silicone. Apply Silicone Gasket and Sealant F6AZ-1 9562-AA or equivalent, to woodruff key slot on crankshaft pulley. See Figure 65. ^ Using Crankshaft Damper Replacer T74P-6316-B, install crankshaft pulley. ^ Loosely install crankshaft pulley bolt. ^ Tighten crankshaft pulley bolt to 90 Nm (66 lb-ft). ^ Loosen crankshaft pulley bolt one (1) full turn. ^ Tighten crankshaft pulley bolt to 47-53 Nm (34-39 lb-ft). ^ Tighten crankshaft pulley bolt an additional 85-90 degrees (1/4 turn). 46. On Romeo engines, proceed as follows: ^ Position power steering pump in installed position. Tighten two (2) upper bolts to 20-30 Nm (15-22 lb-ft). ^ Raise vehicle. ^ Install two (2) power steering pump lower retaining bolts. Tighten bolt to 20-30 Nm (15-22 lb-ft). 47. On 4.6L and 5.4L Windsor engines, proceed as follows: ^ Position power steering pump in installed position. Tighten two (2) upper bolts to 20-30 Nm (15-22 lb-ft). ^ Raise vehicle. ^ Install power steering pump lower retaining bolt. Tighten bolt to 20-30 Nm (15-22 lb-ft). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3214 48. Loosely install four (4) front oil pan bolts. Tighten bolts in sequence shown in Figure 66, in the following two (2) stages: ^ Stage 1: 20 Nm (15 lb-ft). ^ Stage 2: Rotate an additional 60 degrees. 49. Lower vehicle. 50. Using coolant, lubricate new water pump O-ring seal. Install seal on water pump. 51. Install water pump. Tighten retainers in sequence shown in Figure 67, to 20-30 Nm (15-22 lb-ft). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3215 52. Install water pump pulley. Tighten retainers in sequence shown in Figure 68, to 20-30 Nm (15-22 lb-ft). 53. Install radiator. Make sure radiator is sitting on mounting insulators. 54. Install radiator supports. Tighten retainers to 25-35 Nm (18-26 lb-ft). 55. Connect lower radiator hose to radiator. 56. On automatic transmission models, connect transmission cooler lines to radiator. Tighten lines to 16-24 Nm (12-18 lb-ft). 57. Install cooling fan shroud. Tighten retainer 108-10 Nm (71-89 lb-in). 58. Using Fan Clutch Holding Tool T84T-6312-C and Fan Clutch Wrench T93T-6312-B, install cooling fan and clutch assembly. 59. Connect coolant recovery hose to radiator. 60. Install air deflector on top of radiator. 61. Install jack handle on radiator air deflector. 62. Using clean coolant, lubricate coolant tube O-ring seal. Install coolant tube. Tighten retainers on rear of right cylinder head to 40-55 Nm (29-40 lb-ft). NOTE: Make sure left side fuel charge harness is between routing bracket and cylinder head. 63. Install routing bracket and ground strap to rear of right cylinder head. Tighten retainers to 9-12 Nm (80-107 lb-in). 64. Install heater return hose to coolant tube. 65. Install cam cover gaskets on both cam covers. NOTE: The cam cover must be installed within four (4) minutes after applying silicone. 66. Apply Silicone Gasket and Sealant F6AZ-1 9562-AA or equivalent, to the two (2) places where the engine front cover meets the cylinder head. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3216 67. Install right side cam cover. Tighten retainers in sequences shown in Figures 69 and 70, to 8-12 Nm (71-107 lb-in). NOTE: The cam cover must be installed within four (4) minutes after applying silicone. 68. Apply Silicone Gasket and Sealant F6AZ-19562-AA or equivalent, to the two (2) places where the engine front cover meets the cylinder head. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3217 69. Install left side cam cover. Tighten retainers in sequences shown in Figures 71 and 72, to 8-12 Nm (71-107 lb-in). 70. Install new intake manifold gaskets. 71. Install intake manifold (including thermostat housing). Tighten bolts in sequence shown in Figure 73, in the following two (2) stages: ^ Stage 1: 2 Nm (18 lb-in). ^ Stage 2: 20-30 Nm (15-22 lb-ft). 72. Loosely position left side fuel charge harness on cam cover. 73. Connect tuning valve electrical connector. 74. Connect CHT sensor electrical connector. 75. Install alternator assembly. Tighten front alternator bolts to 21-28 Nm (15-21 lb-ft). Tighten alternator bracket bolts to 9-12 Nm (80-106 lb-in). 76. Install drive belt. 77. Using tie strap, retain alternator wiring harness to fuel manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3218 78. On 4.6L engines, proceed as follows: ^ Loosely position right side fuel charge harness on cam cover. ^ Connect water temperature sensor electrical connector. ^ Connect ECT sensor electrical connector. ^ Connect right side ignition wires to spark plugs. ^ Clip ignition wire separators to right cam cover. ^ Connect right side fuel injector electrical connectors. ^ Clip right side fuel charge harness to cam cover. ^ Install right side ignition coil. Tighten retainers to 20-30 Nm (15-22 lb-ft). ^ Connect ignition wires to right side coil. ^ Connect right side radio interference suppressor electrical connector. ^ Connect right side coil pack electrical connector. 79. On 5.4L engines, proceed as follows: ^ Install right side ignition coils. Tighten retainers to 5-7 Nm (44-62 lb-in). ^ Position right side fuel charge harness on cam cover studs. ^ Connect right side fuel injector electrical connectors. ^ Connect right side ignition coil electrical connectors. ^ Connect right side radio interference suppressor. 80. Install PCV valve and line assembly. 81. Connect ground strap to bulkhead. 82. Connect heater return hose to heater core. 83. Install heater supply hose. 84. Install junction block bracket. Tighten retainers securely. 85. Connect single-pin electrical connector. 86. Connect 16-pin electrical connector. 87. Install both 42-pin bulkhead electrical connector halves to junction block bracket. 88. Connect both 42-pin bulkhead electrical connectors. Tighten retainers to 4-5 Nm (35-44 lb-in). 89. Clip two (2) mega-fuses to junction block bracket. 90. Connect positive leads to starter relay. 91. Install junction block bracket splash shield. 92. Connect fuel lines to fuel manifold. 93. On 4.6L engines, proceed as follows: ^ Connect left side ignition wires to spark plugs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3219 ^ Clip ignition wire separators to left cam cover. ^ Connect left side fuel injector electrical connectors. ^ Clip left side fuel charge harness to cam cover. ^ Install left side ignition coil. Tighten retainers to 20-30 Nm (15-22 lb-ft). ^ Connect ignition wires to left side coil. ^ Connect left side radio interference suppressor electrical connector. ^ Connect CMP electrical connector. ^ Connect left side coil pack electrical connector. ^ Connect DPFE transducer electrical connector. ^ Connect IAC motor electrical connector. ^ Connect TP sensor electrical connector. ^ Connect EVR solenoid electrical connector. ^ Connect crankcase vent tube to left cam cover. ^ Position power steering reservoir and bracket in installed position. Tighten upper retainers to 8-12 Nm (71-107 lb-in). Tighten lower retainers to 35-45 Nm (26-33 lb-ft). 94. On 5.4L engines, proceed as follows: ^ Install left side ignition coils. Tighten retainers to 5-7 Nm (44-62 lb-in). ^ Connect left side fuel injector electrical connectors. ^ Connect left side ignition coil electrical connectors. ^ Connect ECT sensor electrical connector. ^ Connect TP sensor electrical connector. ^ Connect EVR solenoid electrical connector. ^ Connect DPFE transducer electrical connector. ^ Connect left side radio interference suppressor electrical connector. ^ Connect IAC motor electrical connector. ^ Connect brake booster vacuum line to throttle body adapter, then install brake booster vacuum line bracket to intake manifold. ^ Connect VMV purge line to top of throttle body adapter. ^ Position vacuum harness on top of motor. ^ Connect vacuum tap to right side of throttle body adapter. ^ Connect EVR solenoid vacuum line. ^ Connect EGR valve vacuum line. ^ Connect fuel pressure regulator vacuum line. ^ Connect vapor management valve vacuum line. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3220 95. Connect EGR tube to EGR valve. Hand-tighten fitting at this time. 96. Connect DPFE transducer hoses to EGR tube. 97. On 4X4 models, connect A/C clutch electrical connector. 98. Raise vehicle. 99. Connect EGR tube to exhaust manifold. Tighten fitting to 35-45 Nm (26-33 lb-ft). 100. On 4X2 models, connect A/C clutch electrical connector. 101. Connect CKP sensor electrical connector. 102. Connect oil pressure switch electrical connector. 103. Lower vehicle. 104. Final tighten EGR tube to valve to 35-45 Nm (26-33 lb-ft). 105. On 4.6L engines, proceed as follows: ^ Loosely position vacuum harness over engine. ^ Connect EVR solenoid vacuum line. ^ Connect EGR valve vacuum line. ^ Connect fuel pressure regulator vacuum line. ^ Connect vapor management valve vacuum line. ^ Position brake booster vacuum line in installed position. Connect line to tap on throttle body adapter. Tighten line retainer at EGR valve to 8-12 Nm (71-106 lb-in). ^ Connect vacuum tap on right side of throttle body adapter. ^ Connect VMV vacuum line at rear of throttle body adapter. 106. On 5.4L engines, proceed as follows: ^ Connect crankcase vent tube to left cam cover. ^ Position power steering reservoir and bracket in installed position. Tighten upper retainers to 8-12 Nm (71-107 lb-in). Tighten lower retainers to 35-45 Nm (26-33 lb-ft). 107. Position accelerator/speed control cables on top of engine. Secure cables to clip on power steering reservoir. 108. Install accelerator cable bracket to intake manifold. Tighten retainer to 6-8 Nm (53-71 lb-in). 109. Connect accelerator cable, speed control cable and return spring to throttle body. 110. Connect upper radiator hose to thermostat housing. 111. Install rear half of air cleaner. 112. Install front half of air cleaner and clean air lube. 113. Connect IAT and MAF electrical connectors. 114. Install throttle body shield. 115. Connect battery negative cable. 116. Remove memory saver. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3221 117. Fill engine with new engine oil. 118. Fill cooling system as follows: ^ Add 50/50 coolant mixture to radiator coolant recovery reservoir. ^ Install radiator cap. ^ Move temperature blend selector to full warm position. ^ Run engine until it reaches operating temperature. ^ Add 50/50 coolant mixture to radiator coolant recovery reservoir until the coolant level is between the "COOLANT FILL LEVEL" marks. ^ Turn off engine and allow cooling system to cool. ^ Repeat bulleted steps until radiator coolant recovery reservoir level remains in between fill level marks when engine is cool. 119. On air suspension equipped models, turn air suspension switch to ON position. 120. Check engine for proper operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3222 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3223 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3224 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3225 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recalls: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3226 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 01-23-6 > Nov > 01 > Engine Coolant - Propylene Glycol Recommendations Coolant: All Technical Service Bulletins Engine Coolant - Propylene Glycol Recommendations Article No. 01-23-6 11/26/01 ^ ENGINE COOLANT - PROPYLENE GLYCOL - FORD MOTOR COMPANY POSITION ON ENGINE COOLANTS MADE FROM PROPYLENE GLYCOL ^ ENGINE COOLANT - PROPYLENE GLYCOL-BASED - FORD MOTOR COMPANY POSITION ON PROPYLENE GLYCOL-BASED ENGINE COOLANTS FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2002 FOCUS 2002 THUNDERBIRD 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT 2000-2002 F-650, F-750 LINCOLN: 1989-1992 MARK VII 1989-2002 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1989-1994 TOPAZ 1989-1997 COUGAR 1989-2002 GRAND MARQUIS, SABLE 1991-1994 CAPRI 1991-1999 TRACER 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER MERKUR: 1989 SCORPIO, XR4TI This article is being republished in its entirety to update the model year coverage. ISSUE This TSB article describes Ford Motor Company's position on the use of propylene glycol-based engine coolants. ACTION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 01-23-6 > Nov > 01 > Engine Coolant - Propylene Glycol Recommendations > Page 3232 Ford Motor Company does not recommend nor endorse the use of engine coolants made with propylene glycol in Ford vehicles. Ford Motor Company currently recommends the use of ethylene glycol-based engine coolants. Published information suggests that engine coolants made with propylene glycol may provide engine cooling performance equivalent to engine coolants made with ethylene glycol. However, different brands of engine coolant provide varying corrosion protection for the cooling system. Ford does not have performance data for the multitude of engine coolants available in the aftermarket and therefore cannot recommend the use of any coolant except those sold by Ford Customer Service Division. Consult the vehicle's Owner's Guide to determine the appropriate Ford Customer Service Division coolant for the vehicle. Furthermore, claims of toxicological and environmental advantages of propylene glycol over ethylene glycol may be misleading. When significant new information is developed, Ford will review this policy. Ford Motor Company specifications recommend that vehicles be maintained using certain ethylene glycol-based engine coolants. Those specifications do not refer to engine coolants made with propylene glycol. Although the Ford New Vehicle Limited Warranty is not automatically voided upon the use of a coolant made with propylene glycol, if such use results in damage to the vehicle or its components, the cost of repairing the damage would not be covered by the Ford New Vehicle Limited Warranty. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-16-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement Technical Service Bulletin # 98B33 Date: 990401 Campaign - Coolant/Cylinder Head Replacement OWNER NOTIFICATION PROGRAM 98B33 Certain 1997 and 1998 Expedition, F-150 and 1998 Navigator vehicles equipped with 4.6L and 5.4L engines for inspection of coolant and, if necessary, replacement of engine cylinder heads ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Refund Codes ^ Attachment II ^ Labor Allowances ^ Parts Requirements ^ Attachment IIIA ^ A - Coolant Test Instructions ^ Attachment IIIB ^ B - Cylinder Head Replacement Instructions ^ Attachment IV ^ Copy of Lincoln Commitment Special Handling Procedure Letter ^ Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3237 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3238 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles on the enclosed list. PROMPTLY CORRECT ^ Affected vehicles on the enclosed list. ^ Other eligible vehicles which are brought to your dealership. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3239 DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with this special handling procedure. CLAIMS Enter claims using DWE. See ACESII Manual. To claim for the "Lincoln Commitment Special Handling", follow the instructions on Attachment IV. OWNER REFUNDS See ACESII Manual, Section 3 for submission procedures. For owner-paid repairs of cracked cylinder heads or damage directly related to cracked cylinder heads made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from servicing dealer), enter using DWE: RENTAL CARS If cylinder head replacement is necessary, Ford will pay for a loaner or rental vehicle except for fuel and insurance which will be at the owner's expense. Do not provide a rental vehicle while cylinder heads are on order. Rentals should be provided only while the vehicle is at the dealership for cylinder head replacement. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number of days vehicle was used in the Miscellaneous Expense area of the recall claim. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3240 COOLANT TESTER Coolant concentrate test kits will be sent at no charge 10 dealers with affected vehicles. Additional stock of testers is limited, but testers may be ordered from the Recall Hotline 1-800-325-5621. PARTS REQUIREMENTS Parts Ordering Information Cylinder head kits can be ordered by calling the Recall Hotline at 1-800-325-5621. The kits listed contain all parts necessary for cylinder head replacement except coolant, oil and oil filter: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3241 DEALER PRICE For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book CLAIMS PREPARATION Enter using DWE. Use code information shown below: ^ Program Code: 98B33 ^ Labor Operation: (see Labor Allowances) See the ACESII manual for detailed instructions. Attachment IIIA - A-Coolant Test Instructions SERVICE PROCEDURE 1. Open hood. 2. Remove coolant recovery bottle cap. 3. Run engine until normal operating temperature (thermostat open) is reached. 4. Insert supplied glycol tester (Thexton 106) into coolant recovery bottle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3242 5. Fill tester to level shown in Figure 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3243 ^ If five (5) or less discs float, refer to Figure 2, no service action is needed. Return vehicle to customer. ^ If all six (6) discs float, indicating "NOT SAFE" glycol condition, see Figure 2, call Recall Hotline at 1-800-325-5621 to order cylinder head kit. Perform cylinder head replacement, when kit arrives. Removal Removal 1. On air suspension equipped vehicles, turn air suspension switch, located in the RH kick panel area, to the OFF position. 2. Install memory saver, then disconnect battery negative cable. 3. Remove shield covering throttle body assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3244 4. Disconnect mass air flow (MAF) sensor electrical connector. Refer to Figure 1. 5. Disconnect intake air temperature (IAT) sensor electrical connector. Refer to Figure 1. 6. Remove air cleaner half and clean air tube as an assembly. See Figure 1. 7. Remove remaining half of air cleaner. 8. Disconnect accelerator cable, speed control cable and return spring from throttle body. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3245 9. Remove accelerator cable bracket from intake manifold, then unclip cables from clip on power steering reservoir bracket. See Figure 2. Position cable assembly aside. 10. On 4.6L engines, proceed as follows: ^ Disconnect vapor management valve (VMV) vacuum line at rear of throttle body adapter. Refer to Figure 3. ^ Disconnect vacuum tap on right side of throttle body adapter. Refer to Figure 3. ^ Disconnect PCV hose at rear of throttle body adapter. Refer to Figure 3. ^ Remove brake booster vacuum line retainer at EGR valve. Disconnect vacuum line at throttle body adapter. See Figure 3. Position line aside. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3246 ^ Disconnect vapor management valve (VMV) vacuum line. Refer to Figure 4. ^ Disconnect fuel pressure regulator vacuum line. Refer to Figure 4. ^ Disconnect EGR valve vacuum line. Refer to Figure 4. ^ Disconnect EVR solenoid vacuum line. See Figure 4. ^ Position vacuum harness away from engine. 11. On 5.4L engines, proceed as follows: ^ Remove power steering reservoir bracket retainers, then position reservoir assembly aside. See Figure 5. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3247 ^ Disconnect crankcase vent tube from left cam cover. Remove vent tube from vehicle. 12. Raise vehicle. 13. Disconnect EGR tube from exhaust manifold. 14. Disconnect oil pressure switch electrical connector. See Figure 6. 15. Disconnect crankshaft position (CKP) sensor electrical connector. See Figure 7. 16. On 4X2 models, disconnect A/C clutch electrical connector. 17. Drain coolant from radiator. NOTE: Do not remove right side cylinder block coolant drain plug. 18. Remove left side cylinder block coolant drain plug. Allow coolant to completely drain. 19. Install cylinder block coolant drain plug. Tighten plug to 16-24 Nm (12-17 lb-ft). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3248 20. Drain engine oil. Do not final tighten drain plug at this time, as it will be removed again. 21. Lower vehicle. NOTE: The best access to the A/C electrical connector is through the wheel well. 22. On 4X4 models, disconnect A/C clutch electrical connector. 23. Mark and disconnect DPFE transducer hoses from EGR tube. 24. Disconnect EGR tube from EGR valve, then remove EGR tube from vehicle. 25. On 4.6L engines, proceed as follows: ^ Remove power steering reservoir bracket retainers, then position reservoir assembly aside. See Figure 8. ^ Disconnect crankcase vent tube from left cam cover. Remove vent tube from vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3249 ^ Disconnect EVR solenoid electrical connector. Refer to Figure 9. ^ Disconnect Throttle Position (TP) sensor electrical connector. Refer to Figure 9. ^ Disconnect Idle Air Control (IAC) motor electrical connector. Refer to Figure 9. ^ Disconnect DPFE transducer electrical connector. See Figure 9. ^ Disconnect left side coil pack electrical connector. Refer to Figure 10. ^ Disconnect camshaft position (CMP) sensor electrical connector. Refer to Figure 10. ^ Disconnect left side radio interference suppressor electrical connector. See Figure 10. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3250 ^ Disconnect ignition wires from left side coil pack. ^ Remove left side coil pack from vehicle. ^ Unclip left side fuel charge harness from cam cover studs. Refer to Figure 11. ^ Unclip ignition wire separators from left cam cover studs. See Figure 11. ^ Disconnect ignition wires from left side spark plugs. Route ignition wires to front of engine. ^ Disconnect left side fuel injector electrical connectors. 26. On 5.4L engines, proceed as follows: ^ Disconnect Vapor Management Valve (VMV) vacuum line. Refer to Figure 12. ^ Disconnect fuel pressure regulator vacuum line. Refer to Figure 12. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3251 ^ Disconnect EGR valve vacuum line. Refer to Figure 12. ^ Disconnect EVR solenoid vacuum line. See Figure 12 ^ Disconnect vacuum tap on right side of throttle body adapter. Refer to Figure 13. ^ Position vacuum harness away from engine. ^ Disconnect VMV purge line at top of throttle body adapter. See Figure 13. ^ Disconnect brake booster vacuum line from throttle body adapter. ^ Remove brake booster vacuum line bracket from intake manifold. Position vacuum line assembly away from intake manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3252 ^ Disconnect Idle Air Control (IAC) motor electrical connector. See Figure 14. ^ Disconnect left side radio interference suppressor electrical connector. Refer to Figure 15. ^ Disconnect DPFE transducer electrical connector. Refer to Figure 15. ^ Disconnect EVR solenoid electrical connector. Refer to Figure 15. ^ Disconnect Throttle Position (TP) sensor electrical connector. Refer to Figure 15. ^ Disconnect Engine Coolant Temperature (ECT) sensor electrical connector. See Figure 15. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3253 ^ Disconnect camshaft position (CMP) sensor electrical connector. See Figure 16. ^ Disconnect ignition coil electrical connectors from left side of engine. Refer to Figure 17. ^ Disconnect fuel injector electrical connectors from left side of engine. See Figure 17. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3254 ^ Remove left side fuel charge harness from cam cover studs, then position harness away from cam cover. See Figure 18. ^ Remove left side ignition coils from vehicle. WARNING DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. WARNING FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. 27. Relieve fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on EFI/CFI fuel pressure gauge. ^ Remove fuel pressure gauge and reinstall schrader valve cap. 28. Disconnect fuel lines from fuel manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3255 29. Remove junction block splash shield. See Figure 19. 30. Disconnect positive leads from starter relay. Refer to Figure 20. 31. Unclip two (2) mega-fuses from bracket. Refer to Figure 20. 32. Disconnect two (2) 42-pin bulkhead electrical connectors. Refer to Figure 20. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3256 33. Remove both bulkhead electrical connector halves from bracket. See Figure 20. 34. Disconnect 16-pin electrical connector. Refer to Figure 21. 35. Disconnect single-pin electrical connector. Refer to Figure 21. 36. Remove junction block bracket. See Figure 21. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3257 37. Remove heater supply hose from vehicle. Refer to Figure 22. 38. Disconnect heater return hose from heater core fitting. Then position hose away from right cam cover. Refer to Figure 22. 39. Remove ground strap to bulkhead retaining bolt, then unwrap ground strap from fuel manifold. See Figure 22. 40. Remove PCV valve and line from vehicle. 41. On 4.6L engines, proceed as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3258 ^ Disconnect right side coil pack electrical connector. Refer to Figure 23. ^ Disconnect right side radio interference suppressor electrical connector. Refer to Figure 23. ^ Disconnect ignition wires from right side coil pack. See Figure 23. ^ Remove right side coil pack from vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3259 ^ Unclip right side fuel charge harness from cam cover studs. Refer to Figure 24. ^ Unclip ignition wire separators from right cam cover studs. See Figure 24. ^ Disconnect ignition wires from right side spark plugs. Route ignition wires to front of engine. ^ Disconnect right side fuel injector electrical connectors. ^ Disconnect Engine Coolant Temperature (ECT) sensor electrical connector. Refer to Figure 25. ^ Disconnect water temperature sender electrical connector. Refer to Figure 25. ^ Remove tie strap retaining alternator wiring harness to fuel manifold. See Figure 25. 42. On 5.4L engines, proceed as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3260 ^ Disconnect right side radio interference suppressor. See Figure 26. ^ Disconnect ignition coil electrical connectors from right side of engine. Refer to Figure 27. ^ Disconnect fuel injector electrical connectors from right side of engine. See Figure 27. ^ Remove right side fuel charge harness from cam cover studs, then position harness away from cam cover. ^ Remove right side ignition coils from vehicle. ^ Remove tie strap retaining alternator wiring harness to fuel manifold. 43. Disconnect upper radiator hose from thermostat housing. 44. Remove drive belt. 45. Remove alternator and mounting bracket as an assembly. The ignition wires and the alternator wiring harness will also be removed with the alternator assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3261 46. Disconnect cylinder head temperature (CHT) sensor electrical connector. Refer to Figure 28. 47. Disconnect tuning valve electrical connector. See Figure 28. 48. Remove the intake manifold retaining bolts. See Figure 29. 49. Remove intake manifold from vehicle. 50. Remove and discard intake manifold gaskets. NOTE: On 5.4L engine, cam cover bolts cannot be separated from cam cover. NOTE: Be careful not to damage cam cover gaskets, as they will be reused. Remove both camshaft covers. 51. Remove both camshaft covers. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3262 52. Disconnect heater return hose from coolant tube, then remove heater hose from vehicle. Refer to Figure 30. 53. Remove retainers securing routing bracket to rear of right-hand cylinder head, then remove routing bracket and ground strap. Refer to Figure 30. 54. Remove coolant tube retainers securing coolant tube to rear of right hand cylinder head, then remove coolant tube. See Figure 30. 55. Remove jack handle from radiator air deflector. 56. Remove air deflector on top of radiator. 57. Disconnect coolant recovery hose from radiator. 58. Using Fan Clutch Holding Tool T84T-6312-C and Fan Clutch Wrench T93T-6312-B, remove cooling fan and clutch assembly. 59. Remove cooling fan shroud. 60. On automatic transmission models, disconnect transmission lines from radiator. 61. Disconnect lower radiator hose from radiator. 62. Remove radiator support brackets, then the radiator. 63. Remove water pump pulley, then the water pump. 64. On 4.6L and 5.4L Windsor engines, proceed as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3263 ^ Remove two (2) upper power steering pump retaining bolts. Refer to Figure 31. ^ Raise vehicle. ^ Remove one (1) lower power steering pump retaining bolt, then position power steering pump away from front engine cover. See Figure 31. 65. On Romeo engines, proceed as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3264 ^ Remove two (2) upper power steering pump retaining bolts. See Figure 32. ^ Raise vehicle. NOTE: One of the following bolts cannot be completely removed from the power steering pump due to clearance with the power steering line. ^ Remove two (2) lower power steering pump retaining bolts, then position power steering pump away from front engine cover. See Figure 33. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3265 66. Remove four (4) front oil pan bolts. See Figure 34. 67. Lower vehicle. 68. Using Crankshaft Damper Remover T58P-6316-D, remove crankshaft pulley. 69. Using Front Cover Seal Remover T74P-6700-A, remove engine front cover oil seal. 70. Remove idler pulley from right side of engine front cover. This pulley blocks a front cover bolt. 71. Remove engine front cover retainers. See Figure 35. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3266 72. Remove engine front cover from engine. See Figure 36. 73. Remove crankshaft sensor ring. 74. Using Crankshaft Holding Tool T93P-6303-A, rotate crankshaft until crankshaft keyway points to the 12 o'clock position. See Figure 37. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3267 75. Install Camshaft Holding Tool T96T-6256-B, on each camshaft. See Figure 38 for holding tool placement. 76. Remove both timing chain tensioners. See Figure 39. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3268 77. Remove both timing chain tensioner guides. See Figure 40. 78. Lift right-hand timing chain off camshaft sprocket, then slide timing chain and crankshaft sprocket off crankshaft. Refer to Figure 41. 79. Lift left-hand timing chain off camshaft sprocket, then slide timing chain and crankshaft sprocket off crankshaft. See Figure 41. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3269 80. Remove both timing chain guides. See Figures 42 and 43. NOTE: Removal of this wheel opening molding screw is necessary to access all screws for the fender splash shield. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3270 81. On 4X4 models, remove one (1) screw shown in Figure 44, from both wheel opening moldings. 82. Remove both front fender splash shields. See Figure 45. 83. Raise vehicle. 84. Disconnect exhaust Y-pipe from exhaust manifolds. 85. Slightly lower vehicle. Exhaust manifold retainers will be accessed through the wheel well opening. 86. Remove left side exhaust manifold and gasket. Retain gasket for reuse. Replace gasket if damaged. 87. Loosen engine oil indicator tube; then turn tube away from cylinder head. Removal of indicator tube is not necessary. 88. Remove right side exhaust manifold and gasket. Retain gasket for reuse. Replace gasket if damaged. 89. Remove retainer securing transmission indicator tube to right cylinder head if equipped. NOTE: Cylinder head bolts that are under the camshaft holding tools cannot be completely removed from the head due to clearance with the holding tool. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3271 Completely loosen these bolts. 90. Remove both cylinder heads. See Figure 46. Discard all cylinder head bolts. 91. Remove and discard both cylinder head gaskets. 92. On Romeo engines, proceed as follows: ^ Remove spark plugs from right cylinder head. ^ Remove camshaft sprocket from right side camshaft. ^ Remove Camshaft Holding Tool from right side camshaft. ^ Install camshaft sprocket on new right side camshaft. Do not final tighten retaining bolt at this time. ^ Remove spark plugs from left cylinder head. ^ Remove camshaft sprocket from left side camshaft. ^ Remove Camshaft Holding Tool from left side camshaft. ^ Install camshaft sprocket on new left side camshaft. Do not final tighten retaining bolt at this time. ^ Remove power steering reservoir bracket and CHT sensor from left cylinder head. 93. On 4.6L and 5.4L Windsor engines, proceed as follows: ^ Remove Camshaft Holding Tools from both camshafts. ^ Remove power steering reservoir bracket and Cylinder Head Temperature sensor from left cylinder head. ^ Remove all eight (8) spark plugs from cylinder heads. 94. Clean the following gasket surfaces: ^ Cylinder block to cylinder head. ^ Engine front cover. ^ Water pump. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3272 ^ Intake manifold. ^ Both cam covers. Installation 1. On all cylinder heads, install one (1) pipe plug into the rear of each cylinder head in locations shown in Figure 47. 2. On 4.6L Romeo engines, install one (1) pipe plug into the front of each cylinder head in locations shown in Figure 48. 3. Install CHT sensor to left cylinder head. Tighten sensor to 24-28 Nm (17-20 lb-ft). 4. Install power steering bracket to left cylinder head. 5. Install all spark plugs (both sides). Tighten plugs to 9-20 Nm (81-178 lb-in). 6. Install right cylinder head gasket. 7. Install right cylinder head. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3273 8. Tighten right cylinder head bolts in sequence shown in Figure 49 in the following three (3) stages: ^ Stage 1: 37-43 Nm (27-32 lb-ft). ^ Stage 2: Rotate 85-95 degrees. ^ Stage 3: Rotate 85-95 degrees. 9. Lubricate all camshaft journals. 10. Install left cylinder head gasket. 11. Install left cylinder head. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3274 12. Tighten left cylinder head bolts in sequence shown in Figure 50 in the following three (3) stages: ^ Stage 1: 37-43 Nm (27-32 lb-ft). ^ Stage 2: Rotate 85-95 degrees. ^ Stage 3: Rotate 85-95 degrees. 13. Lubricate all camshaft journals. 14. Raise vehicle. 15. Install transmission indicator tube retainer to right cylinder head if equipped. Tighten retainer to 18-23 Nm (14-16 lb-ft). 16. Install right side exhaust manifold gasket. NOTE: Due to clearance, the exhaust system Y-pipe mounting flange cannot be positioned on the exhaust manifold outlet after the exhaust manifold is installed on the cylinder head. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3275 17. Install right side exhaust manifold and gasket. Align exhaust system Y-pipe mounting flange with the studs in the exhaust manifold outlet before completely installing the exhaust manifold on the cylinder block. Tighten right side exhaust manifold retainers in sequence shown in Figure 51 to 18-22 Nm (13-16 lb-ft). 18. Position engine oil indicator tube in installed position. 19. Install left side exhaust manifold and gasket. Tighten retainers in sequence shown in Figure 52 to 18-22 Nm (13-16 lb-ft). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3276 20. Remove oil pan drain plug. Completely drain any fluid (oil, coolant) from oil pan. Reinstall drain plug, tightening to 11-16 Nm (98-143 lb-in). 21. Replace oil filter. 22. Install exhaust system Y-pipe to exhaust manifolds. Tighten retainers to 34-46 Nm (25-34 lb-ft). 23. Lower vehicle. 24. Install both fender splash shields. Tighten retainers to 10-13 Nm (89-115 lb-in). 25. On 4X4 models, install one screw removed from both wheel opening moldings. 26. On Romeo engines, proceed as follows: ^ Using socket on camshaft sprocket bolt, rotate left camshaft until timing mark is in 12 o'clock position. Refer to Figure 53. ^ Using socket on camshaft sprocket bolt, rotate right camshaft until timing mark is in 11 o'clock position. Refer to Figure 53. 27. On 4.6L and 5.4L Windsor engines, proceed as follows: ^ Using Camshaft Positioning Tool T96T-6256-AR, rotate left camshaft until timing mark is in 12 o'clock position. Refer to Figure 53. ^ Using Camshaft Positioning Tool T96T-6256-AR, rotate right camshaft until timing mark is in 11 o'clock position. See Figure 53. ^ Install Camshaft Holding Tool T96T-6256-B on each camshaft. 28. On Romeo engines, tighten both camshaft sprocket bolts to 110-130 Nm (81-95 lb-ft). CAUTION Rotate the crankshaft counterclockwise only. Do not rotate past position shown or severe piston and/or valve damage can occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3277 29. Rotate crankshaft using Crankshaft Holding Tool T93P-6303-A. See Figure 54. Fully install holding tool. This will position crankshaft keyway to about 10:30 position. 30. Remove Crankshaft Holding Tool. 31. Compress timing chain tensioner plunger as follows: CAUTION Do not compress the ratchet assembly. This will damage the ratchet assembly. CAUTION Use protective vocers over jaws of vise to prevent damage to tensioner. ^ Compress tensioner plunger using edge of vise. See Figure 55. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3278 ^ Using small screwdriver or pick, push back and hold ratchet mechanism. See Figure 56. ^ While holding ratchet mechanism, push ratchet arm back into tensioner housing. See Figure 57. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3279 ^ Install paper clip into hole in tensioner housing. This will hold ratchet assembly and plunger in during installation. See Figure 58. ^ Remove tensioner from vise. ^ Repeat procedure for second tensioner. 32. If copper links are not visible, mark one (1) link on each end of the timing chain. One link will be an inside link. Use these marks as timing marks. See Figure 59. Repeal this step for other timing chain, if necessary. 33. Install right side timing chain guide. Tighten retainers to 8-12 Nm (71-106 lb-in). 34. Install left side timing chain guide. Tighten retainers to 8-12 Nm (71-106 lb-in). 35. Install timing chains and sprockets as follows: ^ Position left side crankshaft sprocket in left side timing chain. Make sure crankshaft sprocket hub is facing outward. Align mark on timing chain with corresponding dot on crankshaft sprocket. ^ Slide left side sprocket and chain on crankshaft. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3280 ^ Position left side timing chain over camshaft sprocket, aligning timing mark on chain with dot on camshaft sprocket. If necessary, loosen camshaft holding tool and adjust camshaft sprocket to obtain timing mark alignment. Tighten camshaft holding tool after timing marks are aligned. ^ Position right side crankshaft sprocket in right side timing chain. Make sure crankshaft sprocket hub is facing inward. Align mark on timing chain with corresponding dot on crankshaft sprocket. ^ Slide right side sprocket and chain on crankshaft. ^ Position right side timing chain over camshaft sprocket, aligning timing mark on chain with dot on camshaft sprocket. If necessary, loosen camshaft holding tool and adjust camshaft sprocket to obtain timing mark alignment. Tighten camshaft holding tool after timing marks are aligned. ^ Make sure marks on timing chain are lined up with corresponding dots on crankshaft and camshaft sprockets. See Figure 60. ^ Make sure right side crankshaft sprocket is in front of left side crankshaft sprocket with hubs facing each other. See Figure 61. 36. Install right and left timing chain tensioner guides. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3281 37. Install right and left timing chain tensioners. Tighten retainers to 20-30 Nm (15-20 lb-ft). 38. Remove paper clips from both timing chain tensioners. 39. Remove both camshaft holding tools. 40. Install crankshaft sensor ring. 41. Install engine front cover as follows: NOTE: The engine front cover must be installed within four (4) minutes after applying silicone. Apply Silicone Gasket and Sealant F6AZ-1 9562-AA or equivalent, along head to block surface and oil pan to block surface. See Figure 62. ^ Using new gasket, install engine front cover. Align cover with cylinder block dowel. ^ Loosely install engine front cover bolts and stud bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3282 ^ Tighten first five (5) engine front cover bolts in sequence shown in Figure 63, to 20-30 Nm (15-22 lb-ft). ^ Tighten remaining ten (10) engine front cover bolts in sequence shown in Figure 64. On Romeo engines, tighten bolts to 20-30 Nm (15-22 lb-ft). On 4.6L and 5.4L Windsor engines, tighten bolts to 40-55 Nm (29-40 lb-ft). 42. Install right side idler pulley. Tighten retainer to 20-30 Nm (15-22 lb-ft). 43. Using clean engine oil, lubricate engine front cover oil seal inner lip. 44. Using Crankshaft Seal Replacer/Aligner T88T-6701-A, install front cover oil seal. 45. Install crankshaft pulley as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3283 NOTE: The crankshaft pulley must be installed within four (4) minutes after applying silicone. Apply Silicone Gasket and Sealant F6AZ-1 9562-AA or equivalent, to woodruff key slot on crankshaft pulley. See Figure 65. ^ Using Crankshaft Damper Replacer T74P-6316-B, install crankshaft pulley. ^ Loosely install crankshaft pulley bolt. ^ Tighten crankshaft pulley bolt to 90 Nm (66 lb-ft). ^ Loosen crankshaft pulley bolt one (1) full turn. ^ Tighten crankshaft pulley bolt to 47-53 Nm (34-39 lb-ft). ^ Tighten crankshaft pulley bolt an additional 85-90 degrees (1/4 turn). 46. On Romeo engines, proceed as follows: ^ Position power steering pump in installed position. Tighten two (2) upper bolts to 20-30 Nm (15-22 lb-ft). ^ Raise vehicle. ^ Install two (2) power steering pump lower retaining bolts. Tighten bolt to 20-30 Nm (15-22 lb-ft). 47. On 4.6L and 5.4L Windsor engines, proceed as follows: ^ Position power steering pump in installed position. Tighten two (2) upper bolts to 20-30 Nm (15-22 lb-ft). ^ Raise vehicle. ^ Install power steering pump lower retaining bolt. Tighten bolt to 20-30 Nm (15-22 lb-ft). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3284 48. Loosely install four (4) front oil pan bolts. Tighten bolts in sequence shown in Figure 66, in the following two (2) stages: ^ Stage 1: 20 Nm (15 lb-ft). ^ Stage 2: Rotate an additional 60 degrees. 49. Lower vehicle. 50. Using coolant, lubricate new water pump O-ring seal. Install seal on water pump. 51. Install water pump. Tighten retainers in sequence shown in Figure 67, to 20-30 Nm (15-22 lb-ft). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3285 52. Install water pump pulley. Tighten retainers in sequence shown in Figure 68, to 20-30 Nm (15-22 lb-ft). 53. Install radiator. Make sure radiator is sitting on mounting insulators. 54. Install radiator supports. Tighten retainers to 25-35 Nm (18-26 lb-ft). 55. Connect lower radiator hose to radiator. 56. On automatic transmission models, connect transmission cooler lines to radiator. Tighten lines to 16-24 Nm (12-18 lb-ft). 57. Install cooling fan shroud. Tighten retainer 108-10 Nm (71-89 lb-in). 58. Using Fan Clutch Holding Tool T84T-6312-C and Fan Clutch Wrench T93T-6312-B, install cooling fan and clutch assembly. 59. Connect coolant recovery hose to radiator. 60. Install air deflector on top of radiator. 61. Install jack handle on radiator air deflector. 62. Using clean coolant, lubricate coolant tube O-ring seal. Install coolant tube. Tighten retainers on rear of right cylinder head to 40-55 Nm (29-40 lb-ft). NOTE: Make sure left side fuel charge harness is between routing bracket and cylinder head. 63. Install routing bracket and ground strap to rear of right cylinder head. Tighten retainers to 9-12 Nm (80-107 lb-in). 64. Install heater return hose to coolant tube. 65. Install cam cover gaskets on both cam covers. NOTE: The cam cover must be installed within four (4) minutes after applying silicone. 66. Apply Silicone Gasket and Sealant F6AZ-1 9562-AA or equivalent, to the two (2) places where the engine front cover meets the cylinder head. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3286 67. Install right side cam cover. Tighten retainers in sequences shown in Figures 69 and 70, to 8-12 Nm (71-107 lb-in). NOTE: The cam cover must be installed within four (4) minutes after applying silicone. 68. Apply Silicone Gasket and Sealant F6AZ-19562-AA or equivalent, to the two (2) places where the engine front cover meets the cylinder head. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3287 69. Install left side cam cover. Tighten retainers in sequences shown in Figures 71 and 72, to 8-12 Nm (71-107 lb-in). 70. Install new intake manifold gaskets. 71. Install intake manifold (including thermostat housing). Tighten bolts in sequence shown in Figure 73, in the following two (2) stages: ^ Stage 1: 2 Nm (18 lb-in). ^ Stage 2: 20-30 Nm (15-22 lb-ft). 72. Loosely position left side fuel charge harness on cam cover. 73. Connect tuning valve electrical connector. 74. Connect CHT sensor electrical connector. 75. Install alternator assembly. Tighten front alternator bolts to 21-28 Nm (15-21 lb-ft). Tighten alternator bracket bolts to 9-12 Nm (80-106 lb-in). 76. Install drive belt. 77. Using tie strap, retain alternator wiring harness to fuel manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3288 78. On 4.6L engines, proceed as follows: ^ Loosely position right side fuel charge harness on cam cover. ^ Connect water temperature sensor electrical connector. ^ Connect ECT sensor electrical connector. ^ Connect right side ignition wires to spark plugs. ^ Clip ignition wire separators to right cam cover. ^ Connect right side fuel injector electrical connectors. ^ Clip right side fuel charge harness to cam cover. ^ Install right side ignition coil. Tighten retainers to 20-30 Nm (15-22 lb-ft). ^ Connect ignition wires to right side coil. ^ Connect right side radio interference suppressor electrical connector. ^ Connect right side coil pack electrical connector. 79. On 5.4L engines, proceed as follows: ^ Install right side ignition coils. Tighten retainers to 5-7 Nm (44-62 lb-in). ^ Position right side fuel charge harness on cam cover studs. ^ Connect right side fuel injector electrical connectors. ^ Connect right side ignition coil electrical connectors. ^ Connect right side radio interference suppressor. 80. Install PCV valve and line assembly. 81. Connect ground strap to bulkhead. 82. Connect heater return hose to heater core. 83. Install heater supply hose. 84. Install junction block bracket. Tighten retainers securely. 85. Connect single-pin electrical connector. 86. Connect 16-pin electrical connector. 87. Install both 42-pin bulkhead electrical connector halves to junction block bracket. 88. Connect both 42-pin bulkhead electrical connectors. Tighten retainers to 4-5 Nm (35-44 lb-in). 89. Clip two (2) mega-fuses to junction block bracket. 90. Connect positive leads to starter relay. 91. Install junction block bracket splash shield. 92. Connect fuel lines to fuel manifold. 93. On 4.6L engines, proceed as follows: ^ Connect left side ignition wires to spark plugs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3289 ^ Clip ignition wire separators to left cam cover. ^ Connect left side fuel injector electrical connectors. ^ Clip left side fuel charge harness to cam cover. ^ Install left side ignition coil. Tighten retainers to 20-30 Nm (15-22 lb-ft). ^ Connect ignition wires to left side coil. ^ Connect left side radio interference suppressor electrical connector. ^ Connect CMP electrical connector. ^ Connect left side coil pack electrical connector. ^ Connect DPFE transducer electrical connector. ^ Connect IAC motor electrical connector. ^ Connect TP sensor electrical connector. ^ Connect EVR solenoid electrical connector. ^ Connect crankcase vent tube to left cam cover. ^ Position power steering reservoir and bracket in installed position. Tighten upper retainers to 8-12 Nm (71-107 lb-in). Tighten lower retainers to 35-45 Nm (26-33 lb-ft). 94. On 5.4L engines, proceed as follows: ^ Install left side ignition coils. Tighten retainers to 5-7 Nm (44-62 lb-in). ^ Connect left side fuel injector electrical connectors. ^ Connect left side ignition coil electrical connectors. ^ Connect ECT sensor electrical connector. ^ Connect TP sensor electrical connector. ^ Connect EVR solenoid electrical connector. ^ Connect DPFE transducer electrical connector. ^ Connect left side radio interference suppressor electrical connector. ^ Connect IAC motor electrical connector. ^ Connect brake booster vacuum line to throttle body adapter, then install brake booster vacuum line bracket to intake manifold. ^ Connect VMV purge line to top of throttle body adapter. ^ Position vacuum harness on top of motor. ^ Connect vacuum tap to right side of throttle body adapter. ^ Connect EVR solenoid vacuum line. ^ Connect EGR valve vacuum line. ^ Connect fuel pressure regulator vacuum line. ^ Connect vapor management valve vacuum line. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3290 95. Connect EGR tube to EGR valve. Hand-tighten fitting at this time. 96. Connect DPFE transducer hoses to EGR tube. 97. On 4X4 models, connect A/C clutch electrical connector. 98. Raise vehicle. 99. Connect EGR tube to exhaust manifold. Tighten fitting to 35-45 Nm (26-33 lb-ft). 100. On 4X2 models, connect A/C clutch electrical connector. 101. Connect CKP sensor electrical connector. 102. Connect oil pressure switch electrical connector. 103. Lower vehicle. 104. Final tighten EGR tube to valve to 35-45 Nm (26-33 lb-ft). 105. On 4.6L engines, proceed as follows: ^ Loosely position vacuum harness over engine. ^ Connect EVR solenoid vacuum line. ^ Connect EGR valve vacuum line. ^ Connect fuel pressure regulator vacuum line. ^ Connect vapor management valve vacuum line. ^ Position brake booster vacuum line in installed position. Connect line to tap on throttle body adapter. Tighten line retainer at EGR valve to 8-12 Nm (71-106 lb-in). ^ Connect vacuum tap on right side of throttle body adapter. ^ Connect VMV vacuum line at rear of throttle body adapter. 106. On 5.4L engines, proceed as follows: ^ Connect crankcase vent tube to left cam cover. ^ Position power steering reservoir and bracket in installed position. Tighten upper retainers to 8-12 Nm (71-107 lb-in). Tighten lower retainers to 35-45 Nm (26-33 lb-ft). 107. Position accelerator/speed control cables on top of engine. Secure cables to clip on power steering reservoir. 108. Install accelerator cable bracket to intake manifold. Tighten retainer to 6-8 Nm (53-71 lb-in). 109. Connect accelerator cable, speed control cable and return spring to throttle body. 110. Connect upper radiator hose to thermostat housing. 111. Install rear half of air cleaner. 112. Install front half of air cleaner and clean air lube. 113. Connect IAT and MAF electrical connectors. 114. Install throttle body shield. 115. Connect battery negative cable. 116. Remove memory saver. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3291 117. Fill engine with new engine oil. 118. Fill cooling system as follows: ^ Add 50/50 coolant mixture to radiator coolant recovery reservoir. ^ Install radiator cap. ^ Move temperature blend selector to full warm position. ^ Run engine until it reaches operating temperature. ^ Add 50/50 coolant mixture to radiator coolant recovery reservoir until the coolant level is between the "COOLANT FILL LEVEL" marks. ^ Turn off engine and allow cooling system to cool. ^ Repeat bulleted steps until radiator coolant recovery reservoir level remains in between fill level marks when engine is cool. 119. On air suspension equipped models, turn air suspension switch to ON position. 120. Check engine for proper operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3292 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3293 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3294 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3295 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant: > 98B33 > Apr > 99 > Campaign - Coolant/Cylinder Head Replacement > Page 3296 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant: > 01-23-6 > Nov > 01 > Engine Coolant - Propylene Glycol Recommendations Coolant: All Technical Service Bulletins Engine Coolant - Propylene Glycol Recommendations Article No. 01-23-6 11/26/01 ^ ENGINE COOLANT - PROPYLENE GLYCOL - FORD MOTOR COMPANY POSITION ON ENGINE COOLANTS MADE FROM PROPYLENE GLYCOL ^ ENGINE COOLANT - PROPYLENE GLYCOL-BASED - FORD MOTOR COMPANY POSITION ON PROPYLENE GLYCOL-BASED ENGINE COOLANTS FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2002 FOCUS 2002 THUNDERBIRD 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT 2000-2002 F-650, F-750 LINCOLN: 1989-1992 MARK VII 1989-2002 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1989-1994 TOPAZ 1989-1997 COUGAR 1989-2002 GRAND MARQUIS, SABLE 1991-1994 CAPRI 1991-1999 TRACER 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER MERKUR: 1989 SCORPIO, XR4TI This article is being republished in its entirety to update the model year coverage. ISSUE This TSB article describes Ford Motor Company's position on the use of propylene glycol-based engine coolants. ACTION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > All Other Service Bulletins for Coolant: > 01-23-6 > Nov > 01 > Engine Coolant - Propylene Glycol Recommendations > Page 3302 Ford Motor Company does not recommend nor endorse the use of engine coolants made with propylene glycol in Ford vehicles. Ford Motor Company currently recommends the use of ethylene glycol-based engine coolants. Published information suggests that engine coolants made with propylene glycol may provide engine cooling performance equivalent to engine coolants made with ethylene glycol. However, different brands of engine coolant provide varying corrosion protection for the cooling system. Ford does not have performance data for the multitude of engine coolants available in the aftermarket and therefore cannot recommend the use of any coolant except those sold by Ford Customer Service Division. Consult the vehicle's Owner's Guide to determine the appropriate Ford Customer Service Division coolant for the vehicle. Furthermore, claims of toxicological and environmental advantages of propylene glycol over ethylene glycol may be misleading. When significant new information is developed, Ford will review this policy. Ford Motor Company specifications recommend that vehicles be maintained using certain ethylene glycol-based engine coolants. Those specifications do not refer to engine coolants made with propylene glycol. Although the Ford New Vehicle Limited Warranty is not automatically voided upon the use of a coolant made with propylene glycol, if such use results in damage to the vehicle or its components, the cost of repairing the damage would not be covered by the Ford New Vehicle Limited Warranty. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-16-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Capacity 19.2 qts .............................................................................................................................................................. ..................................................... Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 3305 Coolant: Fluid Type Specifications COOLING SYSTEM FLUID, PREMIUM Ford Part No. U.S.A (Except Oregon) ............................................................................................................................................................ E2FZ-19549-AA or -B Canada ............................................................................................................ .............................................................................................. CXC-8-B Oregon .................................. ............................................................................................................................................................. F5FZ-19549-CC Ford Specification ................................................................................................................................ ................................................... ESE-M97B44-A COOLING SYSTEM FLUSH Ford Part No. ....................................................................................................................................... ................................................... F1AZ-19A503-A Ford Specification ................................................. ..................................................................................................................................... ESR-M14P7-A Coolant Mixture with Water ................................................................................................................. ...................................................................... 50% Warning: Do not mix coolant types. Check the owners manual or refer to your local dealer for the correct coolant type. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Drain Plug, Cylinder Block > Component Information > Specifications Coolant Drain Plug: Specifications TORQUE SPECIFICATIONS Cylinder Block Drain Plug ......................................................................................................................................................... 16-24 Nm (11-18 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications Coolant Reservoir: Specifications TORQUE SPECIFICATIONS Coolant Recovery Reservoir Bolts ............................................................................................................................................ 8-10 Nm (71-89 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications > Page 3312 Coolant Reservoir: Description and Operation The radiator coolant recovery reservoir: ^ Pressure is held by the radiator cap. ^ Allows air to escape from the coolant. ^ Is an expansion tank for hot coolant. ^ Is mounted in the left front of the engine compartment. Is the fill point for the cooling system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications > Page 3313 Coolant Reservoir: Service and Repair REMOVAL 1. Partially drain the cooling system. 2. Remove the radiator coolant recovery reservoir hose from the radiator. a. Release the hose clamp and slide away from the hose end. b. Slide the radiator coolant recovery reservoir hose off the radiator fitting. 3. Remove the lower radiator hose from the radiator coolant recovery reservoir. 4. Remove the radiator coolant recovery reservoir. a. Remove the two radiator coolant recovery reservoir bolts. b. Remove the radiator coolant recovery reservoir. INSTALLATION To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 3318 Power Distribution Relay Box The Cooling Fan Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications Radiator Cooling Fan Temperature Sensor / Switch: Specifications Switch Torque Switch Torque Cooling Fan Switch 8-18 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications > Page 3322 Radiator Cooling Fan Temperature Sensor / Switch: Locations Engine View The Engine Coolant Temperature Sensor is located in front of the engine. NOTE: In some applications of the 4.6L engine, the Cylinder Head Temperature (CHT) sensor provides the signal used by the Powertrain Control Module (PCM) in place of the Coolant Temperature Sensor (CTS) for functions such as, but not limited to, activating the electric cooling fans. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications > Page 3323 Radiator Cooling Fan Temperature Sensor / Switch: Description and Operation NOTE: In some applications of the 4.6L engine, the Cylinder Head Temperature (CHT) sensor provides the signal used by the Powertrain Control Module (PCM) in place of the Coolant Temperature Sensor (CTS) for functions such as, but not limited to, activating the electric cooling fans. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Specifications Fan Blade: Specifications TORQUE SPECIFICATIONS Fan Assembly To Fan Clutch Bolts ............................................................................................................................................ 15-20 Nm (11-15 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Specifications > Page 3327 Fan Blade: Description and Operation Fan Blade Assembly The fan blade assembly: ^ Pulls air through the radiator. ^ Is driven by the water pump pulley through a fan clutch. ^ Is mounted on the fan clutch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Specifications > Page 3328 Fan Blade: Service and Repair REMOVAL WARNING: DO NOT RUN THE ENGINE WHILE THE PROTECTIVE COMPONENTS ARE REMOVED. 1. Remove the air cleaner. 2. Drain the cooling system. 3. Remove the front air deflector. a. Remove the screws. b. Remove the front air deflector 4. Remove the upper radiator hose from the radiator. 5. Remove the radiator coolant recovery reservoir hose from the radiator. a. Release the (A) hose clamp and slide it away from the end of the (B) hose. b. Slide the (A) radiator coolant recovery reservoir hose off the (B) radiator fitting. 6. Remove the fan blade assembly and fan clutch. a. Use Fan Clutch Holding Tool to hold the water pump pulley steady. b. Use Fan Clutch Wrench to remove the fan blade and the fan clutch. NOTE: The fan clutch has RH threads. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Specifications > Page 3329 7. Remove the fan shroud. a. Remove the fan shroud screws. b. Lift and remove the fan shroud. 8. Remove the fan blade and fan shroud out of the vehicle together. 9. Separate the fan clutch from the fan blade assembly. a. Remove the fan clutch bolts. b. Separate the (A) fan blade assembly from the (B) fan clutch. INSTALLATION 1. Assemble the fan clutch to the fan blade assembly. a. Position the (A) fan clutch on the (B) fan blade assembly. b. Install the four fan clutch bolts. 2. Position the fan shroud and the fan blade assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Specifications > Page 3330 3. Install the fan shroud. a. Lower the fan shroud onto the radiator clips. b. Install the two fan shroud screws. 4. Install the fan blade assembly and the fan clutch. a. Position the fan blade assembly and the fan clutch on the water pump pulley. b. Use Fan Clutch Holding Tool to hold the water pump pulley steady. c. Use Fan Clutch Wrench to install the fan blade assembly and fan clutch. NOTE: The fan clutch has LH threads. 5. Connect the radiator coolant recovery reservoir hose to the radiator. a. Push the (A) radiator coolant recovery reservoir hose onto the (B) radiator fitting. b. Position and tighten the hose clamp. 6. Connect the upper radiator hose to the radiator. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Specifications > Page 3331 7. Install the front air deflector. a. Position the front air deflector. b. Install the ten front air deflector screws. 8. Fill the cooling system. 9. Install the air cleaner. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Specifications Fan Clutch: Specifications TORQUE SPECIFICATIONS Fan Clutch To Water Pump Pulley ............................................................................................................................................ 47-63 Nm (35-46 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Specifications > Page 3335 Fan Clutch: Description and Operation Fan Clutch The fan clutch: ^ Is a variable fluid drive which connects the water pump pulley to the fan blade assembly. ^ Drives the fan faster when the air temperature is warmer. ^ Is mounted on the water pump pulley. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Specifications > Page 3336 Fan Clutch: Testing and Inspection FAN SPEEDS Spin the fan blade by hand. A light resistance should be felt. If there is no resistance or very high resistance, the minimum and maximum fan speeds must be checked as follows: Minimum Speed Fan Clutch Requirement Test 1. Use a suitable marker to mark the water pump pulley, one of the fan blade retaining bolts and the crankshaft pulley. 2. Connect a tachometer to the engine. 3. Install a throttle adjusting tool. 4. Connect Digital Photoelectric Tachometer. 5. Start the engine and run it at approximately 1500 RPM until the normal operating temperature has been achieved. WARNING: TO AVOID THE POSSIBILITY OF PERSONAL INJURY OR DAMAGE TO THE VEHICLE, DO NOT OPERATE THE ENGINE UNTIL THE FAN BLADE HAS BEEN FIRST EXAMINED FOR POSSIBLE CRACKS AND SEPARATION. 6. Adjust the engine speed to 2307 RPM. 7. Operate the strobe light at 3000 RPM and aim it at the water pump pulley. Adjust the engine speed until the light flash and the water pump pulley mark are synchronized. 8. Aim the strobe light at the fan blade retaining bolts. Adjust the strobe light until the light flash is synchronized with the marked fan blade retaining bolt (the fan blade appears to stand still. 9. The fan blade speed must not be greater than 1500 RPM at 3000 water pump RPM. 10. Turn the engine off. 11. If the fan blade speed was greater than 1500 RPM, replace the water pump. Maximum Speed Fan Clutch Requirement Test 1. Perform Steps 1 through 5 of the Minimum Speed Fan Clutch Requirement Test. 2. Block off areas on each side of the radiator in the engine compartment and the front of the radiator grille. This will raise the temperature of the air striking the fan clutch and should cause the fan to operate at maximum speed. NOTE: The temperature should be above 96° C (205° F) for maximum fan speed. 3. Place the climate control function selector switch in the MAX A/C position and the blower motor switch in the HI position. 4. Adjust the strobe to 3000 RPM. 5. Start the engine and adjust the engine speed until the strobe light flash and the water pump pulley mark are synchronized. WARNING: TO AVOID THE POSSIBILITY OF PERSONAL INJURY OR DAMAGE TO THE VEHICLE, DO NOT OPERATE THE ENGINE UNTIL THE FAN BLADE HAS BEEN FIRST EXAMINED FOR POSSIBLE CRACKS AND SEPARATION. 6. Aim the strobe light at the fan blade retaining bolts. Adjust the strobe light until the light flash is synchronized with the marked fan blade retaining bolt (the fan blade appears to stand still). 7. If the fan blade speed is less than 2300 RPM, replace the fan clutch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Specifications > Page 3337 Fan Clutch: Tools and Equipment Fan Clutch Holding Tool AST tool# 8005 Allows the technician to hold the water pump pulleuy in place while loosening the radiator fan. 2009 Suggested user price: $41.20 Assenmacher Specialty Tools 1 800 525 2943 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Coolant Temperature Sensor Coolant Temperature Sensor/Switch (For Computer): Locations Coolant Temperature Sensor Engine View The Engine Coolant Temperature Sensor is located in front of the engine. NOTE: In some applications of the 4.6L engine, the Cylinder Head Temperature (CHT) sensor provides the signal used by the Powertrain Control Module (PCM) in place of the Coolant Temperature Sensor (CTS) for functions such as, but not limited to, activating the electric cooling fans. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Coolant Temperature Sensor > Page 3343 Engine Views Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3344 Coolant Temperature Sensor/Switch (For Computer): Description and Operation The Engine Coolant Temperature (ECT) sensor: - Sends the PCM a signal indicating engine temperature. - Resistance decreases as coolant temperature increases. NOTE: In some applications of the 4.6L engine, the Cylinder Head Temperature (CHT) sensor provides the signal used by the Powertrain Control Module (PCM) in place of the Coolant Temperature Sensor (CTS) for functions such as, but not limited to, activating the electric cooling fans. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3345 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Partially drain the cooling system. 3. Remove the Engine Coolant Temperature (ECT) sensor . 1 Disconnect the electrical connector. 2 Remove the ECT sensor. INSTALLATION 1. Install the ECT. 2. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications Radiator Cooling Fan Temperature Sensor / Switch: Specifications Switch Torque Switch Torque Cooling Fan Switch 8-18 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications > Page 3349 Radiator Cooling Fan Temperature Sensor / Switch: Locations Engine View The Engine Coolant Temperature Sensor is located in front of the engine. NOTE: In some applications of the 4.6L engine, the Cylinder Head Temperature (CHT) sensor provides the signal used by the Powertrain Control Module (PCM) in place of the Coolant Temperature Sensor (CTS) for functions such as, but not limited to, activating the electric cooling fans. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications > Page 3350 Radiator Cooling Fan Temperature Sensor / Switch: Description and Operation NOTE: In some applications of the 4.6L engine, the Cylinder Head Temperature (CHT) sensor provides the signal used by the Powertrain Control Module (PCM) in place of the Coolant Temperature Sensor (CTS) for functions such as, but not limited to, activating the electric cooling fans. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications Engine Temperature Sensor: Specifications Cylinder Head Temperature (CHT) Sensor 25 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications > Page 3354 Engine Temperature Sensor: Locations Engine View The Cylinder Head Temperature Sensor is located at top front of the engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications > Page 3355 Engine Temperature Sensor: Description and Operation FEATURES The Cylinder Head Temperature (CHT) sensor: - Is mounted into the wall of the cylinder head and is not connected to any coolant passages. Sends a signal to the PCM indicating the cylinder head temperature. - If the temperature exceeds: 130°C (265°F) the PCM disables four fuel injectors at a time. The PCM will alternate which four injectors are disabled every 32 engine cycles. The four cylinders that are not being fuel injected act as air pumps to aid in cooling the engine. - If the temperature exceeds: 166°C (330°F) the PCM disables all of the fuel injectors until the engine temperature drops below: 153°C (308°F) - If the engine reaches critical temperature, the following happens: - The coolant temperature gauge pointer will read fully hot at 121°C (250°F). - The check gauge warning indicator will illuminate. - DTCs are set. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications > Page 3356 Engine Temperature Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the Cylinder Head Temperature (CHT) sensor. 1 Disconnect the electrical connector. 2 Remove the CHT sensor. INSTALLATION 1. Install the CHT. 2. Install the intake manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications Temperature Sensor (Gauge): Specifications TORQUE SPECIFICATIONS Water Temperature Indicator Sending Unit ......................................................................................................................... 16-24 Nm (11.7-17.6 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications > Page 3360 Temperature Sensor (Gauge): Description and Operation The water temperature indicator sender unit: - Provides a gauge signal for coolant temperature. - Is mounted on the top front of the upper intake manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications > Page 3361 Temperature Sensor (Gauge): Service and Repair REMOVAL 1. Partially drain the cooling system. 2. Remove the water temperature indicator sender unit. a. Disconnect the electrical connector. b. Remove the water temperature indicator sender unit. INSTALLATION 1. Install the water temperature indicator sender unit. a. Install the water temperature indicator sender unit. b. Connect the electrical connector. 2. Fill the cooling system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Specifications Fan Shroud: Specifications TORQUE SPECIFICATIONS Fan Shroud Screws ............................................................................................................................. ...................................... 8-10 Nm (71-89 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Specifications > Page 3365 Fan Shroud: Description and Operation The fan shroud: ^ Directs air through the radiator. ^ Protects the fan blade assembly from debris. ^ Prevents injuries. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Customer Interest: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Customer Interest: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3374 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Customer Interest: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3375 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3381 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3382 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 97-19-11 > Sep > 97 > Heater Core - On Car Pressure Test For Warranty Claim Heater Core: All Technical Service Bulletins Heater Core - On Car Pressure Test For Warranty Claim Article No. 97-19-11 09/15/97 COOLING SYSTEM - "ON-VEHICLE" HEATER CORE PRESSURE TEST REQUIRED FOR WARRANTY CLAIM FORD: 1993-97 PROBE, THUNDERBIRD 1993-98 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1995-98 CONTOUR LINCOLN-MERCURY: 1993-97 COUGAR 1993-98 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-98 MYSTIQUE LIGHT TRUCK: 1993-98 ECONOLINE, EXPLORER, F SUPER DUTY, F-150-350 SERIES, RANGER, VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: An "On-Vehicle" heater core pressure test is required before replacing any heater core within the warranty period. ACTION: Perform the "On-Vehicle" heater core pressure test by referring to the following heater core leak test procedure. HEATER CORE LEAK TEST PROCEDURE Use the heater core pressure test to determine if the heater core is leaking. Symptoms associated with a leaking heater core include: ^ Engine coolant leaking into the passenger compartment ^ Engine coolant blown onto the windshield during defrost operation ^ Engine coolant odor inside the passenger compartment 1. Partially drain cooling system. 2. Disconnect both heater core hoses. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 97-19-11 > Sep > 97 > Heater Core - On Car Pressure Test For Warranty Claim > Page 3387 3. Attach two (2) pieces of heater hose to the heater core inlet and outlet tubes and clamp (Figure 1). 4. Install Plug (part of 014-R1072) into one (1) heater hose and clamp (Figure 1). 5. Fill heater core and hoses with water. 6. Install Adapter (part of 0144-R1072) into other heater hose and clamp (Figure 1). 7. Attach Radiator/Heater Core Pressure Tester (014-R1072) to Adapter (part of 014-R1072) (Figure 1). 8. Close the bleed valve and the tester and pump air into the heater core until 241 kPa (35 psi) is reached on the tester gauge. 9. Observe the gauge after 3 minutes. The pressure should not drop. If the pressure does drop, there is a leak. Check the hose connections and retest if you find a leak. 10. Replace heater core if pressure drops and hose connections do not leak. 11. Do not replace heater core if pressure does not drop. Pressure test engine cooling system for leaks elsewhere. 12. Reconnect heater core and refill cooling system after all necessary repairs. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208999, 290000, 402000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Core: > 97-19-11 > Sep > 97 > Heater Core - On Car Pressure Test For Warranty Claim Heater Core: All Technical Service Bulletins Heater Core - On Car Pressure Test For Warranty Claim Article No. 97-19-11 09/15/97 COOLING SYSTEM - "ON-VEHICLE" HEATER CORE PRESSURE TEST REQUIRED FOR WARRANTY CLAIM FORD: 1993-97 PROBE, THUNDERBIRD 1993-98 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1995-98 CONTOUR LINCOLN-MERCURY: 1993-97 COUGAR 1993-98 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-98 MYSTIQUE LIGHT TRUCK: 1993-98 ECONOLINE, EXPLORER, F SUPER DUTY, F-150-350 SERIES, RANGER, VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: An "On-Vehicle" heater core pressure test is required before replacing any heater core within the warranty period. ACTION: Perform the "On-Vehicle" heater core pressure test by referring to the following heater core leak test procedure. HEATER CORE LEAK TEST PROCEDURE Use the heater core pressure test to determine if the heater core is leaking. Symptoms associated with a leaking heater core include: ^ Engine coolant leaking into the passenger compartment ^ Engine coolant blown onto the windshield during defrost operation ^ Engine coolant odor inside the passenger compartment 1. Partially drain cooling system. 2. Disconnect both heater core hoses. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Core: > 97-19-11 > Sep > 97 > Heater Core - On Car Pressure Test For Warranty Claim > Page 3393 3. Attach two (2) pieces of heater hose to the heater core inlet and outlet tubes and clamp (Figure 1). 4. Install Plug (part of 014-R1072) into one (1) heater hose and clamp (Figure 1). 5. Fill heater core and hoses with water. 6. Install Adapter (part of 0144-R1072) into other heater hose and clamp (Figure 1). 7. Attach Radiator/Heater Core Pressure Tester (014-R1072) to Adapter (part of 014-R1072) (Figure 1). 8. Close the bleed valve and the tester and pump air into the heater core until 241 kPa (35 psi) is reached on the tester gauge. 9. Observe the gauge after 3 minutes. The pressure should not drop. If the pressure does drop, there is a leak. Check the hose connections and retest if you find a leak. 10. Replace heater core if pressure drops and hose connections do not leak. 11. Do not replace heater core if pressure does not drop. Pressure test engine cooling system for leaks elsewhere. 12. Reconnect heater core and refill cooling system after all necessary repairs. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208999, 290000, 402000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3394 Heater Core: Specifications Heater Core Bracket Screws ....................................................................................................................................................... 1.5-2.5 N.m (12-22 Lb/In) Heater Core Outlet Bracket Screws ............................................................................................................................................. 1.5-2.5 N.m (13-22 Lb/In) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Auxiliary Heater Core: Description and Operation Auxiliary The auxiliary A/C and heating system uses a rear-mounted heater core. The rear-mounted heater core operates the same as the front-mounted heater core. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Auxiliary > Page 3397 Heater Core: Description and Operation General Information Heater Core The heater core consists of fins and tubes arranged to extract heat from the engine coolant and transfer it to air passing through the heater core. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Page 3398 Heater Core: Testing and Inspection Digital Multimeter Set, A/C Fittings R-134a Automatic Calibration Halogen Leak Detector Radiator/Heater Core Pressure Tester Special Tools HEATER CORE WARNING: CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED AREA SUCH AS A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE CLOSED AREA. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores are good and should not have been replaced. If a heater core leak is suspected, the heater core should be tested as per Plugged Heater Core procedures before pressure testing the heater core. Perform a system inspection by checking the heater system thoroughly as follows: 1. Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A coolant leak in the heater water hose could follow the heater core tube to the heater core and appear as a leak in the heater core. 2. Check the integrity of the heater water hose clamps. 3. Spring-type clamps are installed as original equipment. Use of non-specification clamps can cause leakage at the heater water hose connection Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Page 3399 and damage the heater core. PLUGGED HEATER CORE WARNING: THE HEATER CORE INLET HOSE WILL BECOME TOO HOT TO HANDLE IF THE SYSTEM IS WORKING CORRECTLY. Check to see that the engine coolant is at the proper level. Start the engine and turn on the heater. When the engine coolant reaches operating temperature, feel the heater core outlet hose to see if it is hot. If it is not hot, the heater core may have an air pocket or may be plugged, or the thermostat is not working properly. Pressure Test Use Radiator/Heater Core Pressure Tester to perform the pressure test. 1. Drain the coolant from the cooling system. NOTE: Due to space limitations, a bench test may be necessary for pressure testing. 2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater water hose, approximately 101 mm (4 inches) long on each heater core tube. 4. Fill the heater core and heater water hoses with water and install plug and adapter from Radiator/Heater Core Pressure Tester in the heater water hose ends. Secure the heater water hoses, plug and adapter with hose clamps tightened to specification. 5. Attach the pump and gauge assembly from Radiator/Heater Core Pressure Tester to the adapter. 6. Close the bleed valve at the base of the gauge and pump 241 kPa (35 psi) of air pressure into the heater core. 7. Observe the pressure gauge for a minimum of three minutes. 8. If the pressure drops, check the heater water hose connections to the core tubes for leaks. If the heater water hoses do not leak, test the heater core as follows: 1. Drain all coolant from the heater core. 2. Remove the heater core from the A/C evaporator housing. 3. Connect the 101 mm (4 inches) test heater water hoses with plug and adapter to the core tubes. Then connect Radiator/Heater Core Pressure Tester to the adapter. 4. Apply 241 kPa (35 psi) of air pressure to the heater core. Submerge the heater core in water. 5. If a leak is observed, service or replace the heater core. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Back Flushing-Heater Core Heater Core: Service and Repair Back Flushing-Heater Core 1. Release the pressure in the cooling system by slowly turning the radiator cap one turn counterclockwise. When the pressure is released, remove the radiator cap. WARNING: DO NOT OPEN THE COOLING SYSTEM WHILE IT IS HOT OR WHILE THE ENGINE IS RUNNING. 2. Partially drain the cooling system. 3. Remove the two heater hoses from the engine. a. Slide the (A) hose clamp away from the end of the (B) heater inlet hose. b. Remove the heater inlet hose. c. Slide the (A) hose clamp away from the end of the (By heater outlet hose. d. Remove the heater outlet hose. 4. Use cooling system Flush-All, Flush Kit Hardware Package and Drain Kit to back flush heater core with Ford Premium Cooling System Flush F1AZ-19A503-A or equivalent meeting Ford specification ESR-M14P7-A. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Back Flushing-Heater Core > Page 3402 5. Install the heater hoses. a. Position the heater inlet hose. b. Slide the (A) hose clamp toward the end of the (B) heater inlet hose. c. Position the heater outlet hose. d. Slide the (C) hose clamp toward end of (D) heater outlet hose. 6. Fill the cooling system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Back Flushing-Heater Core > Page 3403 Heater Core: Service and Repair Removal and Installation Front REMOVAL 1. Disconnect the battery ground cable. 2. Drain the radiator. Refer to: "Engine, Cooling and Exhaust : Cooling System : Service and Repair" See: Service and Repair 3. Remove the instrument panel. Refer to: "Body and Frame : Interior Trim : Dash Board : Service and Repair" See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 4. Compress the holding tabs and disconnect the heater water hoses at the heater core. 5. Remove the A/C plenum demister adapter. 1. Remove the screw. 2. Remove the A/C plenum demister adapter. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Back Flushing-Heater Core > Page 3404 6. Disconnect the vacuum line. 7. Remove the heater core bracket. 1. Remove the two screws. 2. Remove the bracket. 8 Remove the plenum assembly top. 1. Remove the 13 screws. 2. Remove the plenum assembly top. 9. Remove the blend door assembly from the case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Back Flushing-Heater Core > Page 3405 10. Remove the heater core. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Auxiliary REMOVAL Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Back Flushing-Heater Core > Page 3406 1. Remove the plenum assembly. Refer to: "Heater Core Case : Service and Repair" See: Heating and Air Conditioning/Heater Core Case/Service and Repair 2. Remove the evaporator/heater core access cover. 1. Remove the ten bolts. 2. Remove the evaporator/heater core access cover. 3. Remove the heater core. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Page 3407 Heater Core: Tools and Equipment Digital Multimeter Set, A/C Fittings R-134a Automatic Calibration Halogen Leak Detector Radiator/Heater Core Pressure Tester Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3416 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3417 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3423 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3424 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes Service Tip. Heater Hose: All Technical Service Bulletins Rear Air Conditioning Lines/Tubes - Service Tip. Article No. 97-14-20 07/07/97 ^ AIR CONDITIONING - REAR AUXILIARY UNDERBODY A/C LINES AND TUBES - SERVICE TIP ^ COOLING SYSTEM - REAR AUXILIARY UNDERBODY HEATER LINES AND TUBES SERVICE TIP LIGHT TRUCK: 1997 EXPEDITION ISSUE: Additional information has been released by Ford Motor Company regarding the servicing of the underbody tubes and hoses for the rear auxiliary A/C and heater systems. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes Service Tip. > Page 3429 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes Service Tip. > Page 3430 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes Service Tip. > Page 3431 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes Service Tip. > Page 3432 ACTION: When servicing the underbody tubes and hoses for the rear auxiliary A/C and heater, refer to the following illustrations (Figures 1-4) to determine correct part number and part locations. Refer to the 1997 Expedition Workshop Manual for all part removal and installation procedures. PART NUMBER PART NAME F75Z-18663-KA Front Heater Outlet Tube Kit F75Z-18696-KA Front Heater Inlet Tube Kit F75Z-18663-LA Rear Heater Outlet Tube Kit F75Z-18696-LA Hear Heater Inlet Tube Kit F75Z-19867-KA Rear A/C Suction Tube Kit F75Z-19835-JA Rear A/C Liquid Tube Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes Service Tip. > Page 3433 OASIS CODES: 208100, 208200, 208999, 290000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > NHTSA98V095000 > May > 98 > Recall 98V095000: Lug Nut Replacement Wheel Fastener: All Technical Service Bulletins Recall 98V095000: Lug Nut Replacement Year: 1997, 1998 Make: LINCOLN TRUCK, FORD TRUCK Model: NAVIGATOR, EXPEDITION, F150, F250 Year of Recall: '98 Type of Report: Vehicle Potential Number of Units Affected: 1520000 Summary: Vehicle Description: Multi-purpose vehicles and light duty pickup trucks. The lug nuts on these vehicles may not create sufficient clamp load allowing wheel movement in relation to the hub/rotor mounting surface. This can result in the loosening of lug nuts, stud fatigue failure, and the potential for a wheel separation from the vehicle, increasing the risk of a vehicle crash. Dealers will inspect the wheel studs and replace the wheel lug nuts. Owner notification is expected to begin July 20, 1998. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure Wheel Fastener: All Technical Service Bulletins Lug Nuts - Proper Installation/Torqueing Procedure Article No. 98-5A-4 ^ BRAKES - PREVENTING BRAKE VIBRATION - SERVICE TIP ^ WHEELS - PROPER LUG TORQUE PROCEDURES - SERVICE TIP FORD: 1972-97 THUNDERBIRD 1976-86 LTD 1976-97 MUSTANG 1981-97 CROWN VICTORIA 1982-88 EXP 1982-98 ESCORT 1984-94 TEMPO 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1979-83 MONARCH, ZEPHYR 1979-97 COUGAR 1980-83 MARK VI 1980-98 CONTINENTAL, TOWN CAR 1981-86 LYNX 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-97 SABLE 1987-89 TRACER 1987-97 GRAND MARQUIS 1991-94 CAPRI 1991-97 TRACER 1993-98 MARK VIII 1995-98 MYSTIQUE LIGHT TRUCK: 1979-96 BRONCO 1979-97 ECONOLINE, F-150-350 SERIES 1984-90 BRONCO II 1984-97 RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-98 WINDSTAR 1997 EXPEDITION 1998 NAVIGATOR ISSUE: The use of air impact tools to tighten wheel lug nuts can lead to overtightened and/or unevenly tightened wheel lug nuts. Air impact tools typically used for wheel lug nut removal and installation can generate up to 475 N.m (350 lb-ft) of torque. Overtightened and/or unevenly torqued wheel lug nuts may cause: ^ Brake vibration ^ Distortion of the wheel hub ^ Distortion of the brake rotor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure > Page 3443 ^ Brake rotor runout ^ Damage to the wheel ^ Damage to the wheel nuts and studs ACTION: All wheel lug nuts should only be tightened to specification using a torque wrench or by using the Rotunda ACCUTORO 164-R0314 or equivalent on a 1/2" drive air impact tool. The "ACCUTORO" lug nut sockets limit the torque of the air impact tool, preventing overtightening or uneven tightening of the wheel lug nuts. The torque limiting devices (regulators) on air impact tools will not reduce the output torque enough to prevent overtightening of the wheel lug nuts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure > Page 3444 NOTE: REFER TO THE APPROPRIATE SERVICE MANUAL OR THE CHART IN FIGURE 1 FOR THE CORRECT WHEEL LUG NUT TORQUE SPECIFICATION. THE CHART IN FIGURE 1 ALSO PROVIDES THE CORRECT "ACCUTORO" LUG NUT SOCKET TO USE. The "ACCUTORO" socket is intended for lug nut installation, not removal. When using the "ACCUTORO" socket, the output torque of the air impact tool must be set to 217-339 N.m (160-250 lb-ft), usually this will be the lowest setting on the air impact tool. The "ACCUTORO" lug nut sockets are available through Rotunda Equipment. The four-piece set (164-R0314) fits most Ford Motor Company cars and light trucks. The tool set consists of four (4) lug nut sockets and a storage case. The set can be ordered by calling Rotunda Equipment at 1-800-ROT-UNDA (768-8632). CAUTION: AIR IMPACT TOOLS SHOULD NOT BE USED TO TIGHTEN WHEEL LUG NUTS UNLESS THE "ACCUTORO" LUG NUT SOCKET OF THE CORRECT SPECIFICATION IS USED. NOTE: DO NOT USE AIR IMPACT TOOLS ON LOCKING WHEEL LUG NUTS. THEY ARE TO BE HAND-TORQUED ONLY. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-17-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 303000, 306000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure > Page 3454 ^ Brake rotor runout ^ Damage to the wheel ^ Damage to the wheel nuts and studs ACTION: All wheel lug nuts should only be tightened to specification using a torque wrench or by using the Rotunda ACCUTORO 164-R0314 or equivalent on a 1/2" drive air impact tool. The "ACCUTORO" lug nut sockets limit the torque of the air impact tool, preventing overtightening or uneven tightening of the wheel lug nuts. The torque limiting devices (regulators) on air impact tools will not reduce the output torque enough to prevent overtightening of the wheel lug nuts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure > Page 3455 NOTE: REFER TO THE APPROPRIATE SERVICE MANUAL OR THE CHART IN FIGURE 1 FOR THE CORRECT WHEEL LUG NUT TORQUE SPECIFICATION. THE CHART IN FIGURE 1 ALSO PROVIDES THE CORRECT "ACCUTORO" LUG NUT SOCKET TO USE. The "ACCUTORO" socket is intended for lug nut installation, not removal. When using the "ACCUTORO" socket, the output torque of the air impact tool must be set to 217-339 N.m (160-250 lb-ft), usually this will be the lowest setting on the air impact tool. The "ACCUTORO" lug nut sockets are available through Rotunda Equipment. The four-piece set (164-R0314) fits most Ford Motor Company cars and light trucks. The tool set consists of four (4) lug nut sockets and a storage case. The set can be ordered by calling Rotunda Equipment at 1-800-ROT-UNDA (768-8632). CAUTION: AIR IMPACT TOOLS SHOULD NOT BE USED TO TIGHTEN WHEEL LUG NUTS UNLESS THE "ACCUTORO" LUG NUT SOCKET OF THE CORRECT SPECIFICATION IS USED. NOTE: DO NOT USE AIR IMPACT TOOLS ON LOCKING WHEEL LUG NUTS. THEY ARE TO BE HAND-TORQUED ONLY. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-17-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 303000, 306000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Page 3456 Heater Hose: Specifications Hose Clamp ......................................................................................................................................... ........................................ 1.6-2.2 N.m (17-22 Lb/In) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Page 3457 Heater Hose: Description and Operation The supply lines are one-piece tubes that are secured to the underbody of the vehicle. Replacement kits are only available with multiple-piece lines for ease of installation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Outlet Tube Heater Hose: Service and Repair Front Outlet Tube Heater Hose Disconnect Tool Special Tools REMOVAL 1. Drain the cooling system. 2. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 3. Remove the RH front fender splash shield. 1. Remove the five screws. 2. Remove the three pushpins. 3. Remove the front fender splash shield. 4. Remove the four tube brackets. 1. Remove the nuts. 2. Remove the bracket by inserting a screw driver in the bracket slot and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the tubes. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 3460 5. Disconnect the heater outlet tube from the outlet hose. ^ Use Heater Hose Disconnect Tool to disconnect the hose. 6. Disconnect the front auxiliary heater outlet tube from the rear auxiliary heater outlet tube. 1. Remove the nut. 2. Disconnect the line. 7. Cut the heater outlet tube in the positions shown. 8. Remove and discard the cut sections. INSTALLATION 1. Install the heater outlet tube. ^ In stall the end with blue tape over the frame. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 3461 2. Install the heater outlet tube. ^ Install the end with red tape over the frame and the end with yellow tape between the frame and the body vertical flange. 3. Connect the heater water outlet tubes. 1. Connect the fitting. 2. Loosely install the nut. 4. Install the heater water outlet tube. ^ Install the tube through the wheel opening. 5. Connect the heater water outlet tubes. 1. Connect the fitting. 2. Loosely install the nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 3462 6. Tighten the two peanut fittings. 7. Install the tube brackets. 1. Position the bracket. 2. Install the nut. ^ Snap the tube into the bracket. CAUTION: Insure that clearance exists between the frame and the tubes. NOTE: The bracket must be positioned equally between the white location marks on the tube. 8. Connect heater water outlet tube to engine heater outlet hose. 9. Install the front fender splash shield. 10. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 3463 11. Fill the cooling system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 3464 Heater Hose: Service and Repair Rear Inlet Tube Heater Hose Disconnect Tool Special Tools REMOVAL 1. Drain the cooling system. 2. Remove the quarter trim panel access cover. 3. Disconnect the heater inlet hose. ^ Use Heater Hose Disconnect Tool to disconnect the inlet hose. 4. Remove the auxiliary A/C line grommet retainer. 1. Remove the bolts. 2. Remove the retainer. 5. Remove the spare tire. 6. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 3465 7. Lower the muffler heat shield. 1. Remove the two front bolts. 2. Lower the heat shield. 8. Remove the four tube brackets. 1. Remove the nuts. 2. Remove the bracket by inserting a screw driver in the bracket slot and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the tubes. 9. Cut the tube in the positions shown. 10. Remove and discard the cut sections. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 3466 1. Install the heater inlet tube. ^ Install the end with green tape over the axle between the frame and body. 2. Connect the heater inlet tube to the front auxiliary line. 1. Connect the inlet tube. 2. Loosely install the nut. 3. Install the heater inlet tube. ^ Install the end with blue tape between the frame crossmember and the floor pan. 4. Connect the heater inlet tubes. 1. Connect the fittings. 2. Loosely install the nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 3467 5. Install the heater inlet tube. ^ In stall the end with red tape between the frame and the body. 6. Connect the heater tubes. 1. Connect the fittings. 2. Loosely install the nut. 7. Install the heater inlet rube. ^ Install the end with green tape through the floor opening. 8. Connect the heater inlet tubes. 1. Connect the fittings. 2. Loosely install the nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 3468 9. Tighten the four peanut fittings. 10. Install the tube brackets. 1. Position the bracket. 2. Install the nut. ^ Snap the tube into the bracket. NOTE: The bracket must be positioned equally between the white location marks on the tube. 11. Install the muffler heat shield. 1. Position the shield. 2. Install the nuts 12. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. 13. Install the grommet tube seal and retainer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 3469 NOTE: Insure that the tubes are entering through the center of the floor opening and that the retainer locating marks are positioned correctly. 14. Connect the heater inlet hose to the auxiliary heater core. 15. Install the quarter trim access panel. 16. Install the spare tire. 17. Fill the cooling system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 3470 Heater Hose: Service and Repair Rear Outlet Tube Heater Hose Disconnect Tool Special Tools REMOVAL 1. Drain the cooling system. 2. Remove the quarter trim panel access cover. 3. Disconnect the heater outlet hose. ^ Use Heater Hose Disconnect Tool to disconnect the outlet hose. 4. Remove the auxiliary A/C line grommet retainer. 1. Remove the bolts. 2. Remove the retainer. 5. Remove the spare tire. 6. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 3471 7. Lower the muffler heat shield. 1. Remove the two front bolts. 2. Lower the heat shield. 8. Remove the four tube brackets. 1. Remove the nuts. 2. Remove the bracket by inserting a screw driver in the bracket slot and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off. 9. Cut the tube in the positions shown. 10. Remove and discard the cut sections. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 3472 1. Install the heater outlet tube. ^ Install the end with blue tape over the axle between the frame and the body. 2. Connect the heater outlet tube to the front auxiliary tube. 1. Connect the fittings. 2. Loosely install the nut. 3. Install the heater outlet tube. ^ Install the end with red tape between the frame and the crossmember. 4. Connect the heater outlet tubes. 1. Connect the fittings. 2. Loosely install the nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 3473 5. Install the heater outlet tube. ^ Install the end with blue tape between the frame and body. 6. Connect the heater outlet tubes. 1. Connect the fittings. 2. Loosely install the nut. 7. Install the heater outlet tube. ^ Install the end with the hose through the floor opening. 8. Tighten the four peanut fittings. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 3474 9. Install the tube brackets. 1. Position the bracket. 2. Install the nut. ^ Snap the tube into the bracket. NOTE: The bracket must be positioned equally between the white location marks on the tube. 10. Install the muffler heat shield. 1. Position the shield. 2. Install the nuts. 11. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. 12. Install the grommet tube seal and retainer. NOTE: Insure that the tubes are entering through the center of the floor opening and that the retainer locating marks are positioned correctly. 13. Connect the heater outlet hose to the auxiliary heater core. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 3475 14. Install the quarter trim access panel. 15. Install the spare tire. 16. Fill the cooling system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 3476 Heater Hose: Service and Repair Removal and Installation REMOVAL 1. Drain the radiator. 2. Disconnect the heater outlet hose at the engine. 3. Disconnect the heater inlet hose at the engine. 1. Loosen the hose clamp. 2. Disconnect the heater inlet hose. 4. Compress the holding tabs and disconnect the heater water hoses at the heater core. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 3477 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Testing and Inspection Temperature Gauge: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug > Component Information > Description and Operation Radiator Drain Plug: Description and Operation The radiator draincock: ^ Is used to empty coolant from the system. ^ Is mounted at the bottom RH side of the radiator. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Specifications Radiator Cap: Specifications Pressure Relief Cap Opening Pressure ..................................................................................................................................................... 110 kPa (16 psi) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Specifications > Page 3489 Radiator Cap: Description and Operation The radiator cap: ^ Seals the cooling system. ^ Relieves excess pressure in the cooling system. ^ Provides an increase in pressure to increase coolant boiling temperature to prevent overheating. ^ Is mounted on the radiator coolant recovery reservoir. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Specifications > Page 3490 Radiator Cap: Testing and Inspection WARNING: NEVER REMOVE THE PRESSURE RELIEF CAP UNDER ANY CONDITIONS WHILE THE ENGINE IS OPERATING. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DAMAGE TO THE COOLING SYSTEM OR ENGINE AND/OR PERSONAL INJURY. TO AVOID HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE COOLING SYSTEM, USE EXTREME CARE WHEN REMOVING THE PRESSURE RELIEF CAP FROM A HOT RADIATOR COOLANT RECOVERY RESERVOIR. WAIT UNTIL THE ENGINE HAS COOLED, THEN WRAP A THICK CLOTH AROUND THE PRESSURE RELIEF CAP AND TURN IT SLOWLY ONE TURN (COUNTERCLOCKWISE). STEP BACK WHILE THE PRESSURE IS RELEASED FROM THE COOLING SYSTEM. WHEN CERTAIN ALL THE PRESSURE HAS BEEN RELEASED, REMOVE PRESSURE RELIEF CAP (STILL WITH A CLOTH). 1. Remove the pressure relief cap from the radiator coolant recovery reservoir. 2. Immerse the pressure relief cap in water and install it on the shallow filler neck of Radiator/Heater Core Pressure Tester and Radiator Cap Adapter, part of Radiator/Heater Core Pressure Tester. 3. Immerse the filler neck seal in water and install it in the filler neck adapter. 4. Install the filler neck adapter with the filler neck seal to Radiator Cap Adapter. 5. Connect the female quick-connect fitting of the pressure test pump to the male quick-connect fining of the filler neck adapter. 6. Slowly depress the plunger of the pressure test pump until the pressure gauge reading stops increasing and note the highest pressure reading obtained. NOTE: If the plunger of the pump is depressed too fast, an erroneous pressure reading will result. 7. Release the pressure by turning the relief screw counterclockwise. Then tighten the pressure relief screw and repeat Step 6 (at least twice) to ensure the reading is repeatable within the specifications of the pressure relief cap. 8. If the pressure test gauge readings are not within specifications, replace the pressure relief cap. If the pressure test gauge readings are within specifications, perform the cooling system Pressure Test. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Description and Operation Radiator Hose: Description and Operation The lower radiator hose: ^ Is equipped with a new style quick connect fitting at the radiator connection. ^ Can be disconnected and connected from the radiator without replacing the O-rings or the shrink band clamp. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Hoses (Lower) Radiator Hose: Service and Repair Radiator Hoses (Lower) REMOVAL 1. Drain the cooling system. 2. Remove inlet side of air cleaner assembly. 3. Disconnect the lower radiator hose from the water pump. 4. Disconnect the lower radiator hose from the radiator coolant recovery reservoir. 5. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 6. If equipped with engine oil cooler, disconnect the lower radiator hose connections from the oil cooler. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Hoses (Lower) > Page 3496 7. Disconnect the lower radiator hose from the radiator. a. Pry the locking tab up and out of the slot. b. Rotate the hose. c. Disconnect and remove the hose. INSTALLATION To install, reverse the removal procedure. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. The lower radiator hose does not require rotation for installation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Hoses (Lower) > Page 3497 Radiator Hose: Service and Repair Radiator Hoses (Upper) REMOVAL 1. Partially drain the cooling system. 2. Remove the upper radiator hose. a. Release the two hose clamps and slide away from the hose ends. b. Remove the upper radiator hose. INSTALLATION 1. Install the upper radiator hose. a. Position the upper radiator hose. b. Compress and position the hose clamps. NOTE: Ensure that the hose is seated in the upper hose support bracket. 2. Fill the cooling system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 3502 Power Distribution Relay Box The Cooling Fan Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Coolant Temperature Sensor Coolant Temperature Sensor/Switch (For Computer): Locations Coolant Temperature Sensor Engine View The Engine Coolant Temperature Sensor is located in front of the engine. NOTE: In some applications of the 4.6L engine, the Cylinder Head Temperature (CHT) sensor provides the signal used by the Powertrain Control Module (PCM) in place of the Coolant Temperature Sensor (CTS) for functions such as, but not limited to, activating the electric cooling fans. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Coolant Temperature Sensor > Page 3509 Engine Views Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3510 Coolant Temperature Sensor/Switch (For Computer): Description and Operation The Engine Coolant Temperature (ECT) sensor: - Sends the PCM a signal indicating engine temperature. - Resistance decreases as coolant temperature increases. NOTE: In some applications of the 4.6L engine, the Cylinder Head Temperature (CHT) sensor provides the signal used by the Powertrain Control Module (PCM) in place of the Coolant Temperature Sensor (CTS) for functions such as, but not limited to, activating the electric cooling fans. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3511 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Partially drain the cooling system. 3. Remove the Engine Coolant Temperature (ECT) sensor . 1 Disconnect the electrical connector. 2 Remove the ECT sensor. INSTALLATION 1. Install the ECT. 2. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications Radiator Cooling Fan Temperature Sensor / Switch: Specifications Switch Torque Switch Torque Cooling Fan Switch 8-18 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications > Page 3515 Radiator Cooling Fan Temperature Sensor / Switch: Locations Engine View The Engine Coolant Temperature Sensor is located in front of the engine. NOTE: In some applications of the 4.6L engine, the Cylinder Head Temperature (CHT) sensor provides the signal used by the Powertrain Control Module (PCM) in place of the Coolant Temperature Sensor (CTS) for functions such as, but not limited to, activating the electric cooling fans. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications > Page 3516 Radiator Cooling Fan Temperature Sensor / Switch: Description and Operation NOTE: In some applications of the 4.6L engine, the Cylinder Head Temperature (CHT) sensor provides the signal used by the Powertrain Control Module (PCM) in place of the Coolant Temperature Sensor (CTS) for functions such as, but not limited to, activating the electric cooling fans. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications Engine Temperature Sensor: Specifications Cylinder Head Temperature (CHT) Sensor 25 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications > Page 3520 Engine Temperature Sensor: Locations Engine View The Cylinder Head Temperature Sensor is located at top front of the engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications > Page 3521 Engine Temperature Sensor: Description and Operation FEATURES The Cylinder Head Temperature (CHT) sensor: - Is mounted into the wall of the cylinder head and is not connected to any coolant passages. Sends a signal to the PCM indicating the cylinder head temperature. - If the temperature exceeds: 130°C (265°F) the PCM disables four fuel injectors at a time. The PCM will alternate which four injectors are disabled every 32 engine cycles. The four cylinders that are not being fuel injected act as air pumps to aid in cooling the engine. - If the temperature exceeds: 166°C (330°F) the PCM disables all of the fuel injectors until the engine temperature drops below: 153°C (308°F) - If the engine reaches critical temperature, the following happens: - The coolant temperature gauge pointer will read fully hot at 121°C (250°F). - The check gauge warning indicator will illuminate. - DTCs are set. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications > Page 3522 Engine Temperature Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the Cylinder Head Temperature (CHT) sensor. 1 Disconnect the electrical connector. 2 Remove the CHT sensor. INSTALLATION 1. Install the CHT. 2. Install the intake manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications Temperature Sensor (Gauge): Specifications TORQUE SPECIFICATIONS Water Temperature Indicator Sending Unit ......................................................................................................................... 16-24 Nm (11.7-17.6 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications > Page 3526 Temperature Sensor (Gauge): Description and Operation The water temperature indicator sender unit: - Provides a gauge signal for coolant temperature. - Is mounted on the top front of the upper intake manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications > Page 3527 Temperature Sensor (Gauge): Service and Repair REMOVAL 1. Partially drain the cooling system. 2. Remove the water temperature indicator sender unit. a. Disconnect the electrical connector. b. Remove the water temperature indicator sender unit. INSTALLATION 1. Install the water temperature indicator sender unit. a. Install the water temperature indicator sender unit. b. Connect the electrical connector. 2. Fill the cooling system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Testing and Inspection Temperature Gauge: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications - The water thermostat should initially open at 87-91° C (188-195° F), and be fully opened at 100° C (212° F). NOTE: "Fully open" means the water thermostat lifts a distance of 8.0 mm (0.31 in) or more. - The water thermostat should be closed at 85° C (185° F). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 3534 Thermostat: Description and Operation The water thermostat: ^ Opens to allow coolant to flow into the radiator. ^ Closes to keep coolant in the engine block and heater circuit. ^ Is mounted in the upper intake manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 3535 Thermostat: Testing and Inspection NOTE: Overheating or failure to reach normal operating temperature can indicate improper water thermostat operation. The water thermostat must be removed from the vehicle and temperature-tested. Ensure that the cause of the problem is not a leaking system or a problem with the engine or water pump before removing the water thermostat. 1. Check the cold engine coolant level in the radiator coolant recovery reservoir. Replenish it if necessary. 2. Start the engine and allow it to run for 10 minutes. 3. Feel the inlet and heater water hoses and the underside of the upper radiator hose. If these hoses are still cold after 10 minutes of operation, remove the water thermostat. 4. Suspend the water thermostat and an accurate thermometer in a suitable container that will not allow the test pieces to touch the bottom. 5. Fill the container with water, completely covering the water thermostat. 6. Heat the water until boiling, while observing the thermometer temperature. 7. The water thermostat should initially open at 87-91° C (188-195° F), and be fully opened at 100° C (212° F). NOTE: "Fully open" means the water thermostat lifts a distance of 8.0 mm (0.31 in) or more. 8. Start to cool the water thermostat. 9. The water thermostat should be closed at 85° C (185° F). 10. If the water thermostat does not operate as indicated, replace the water thermostat. 11. To check for low temperature leakage, cool the water thermostat to room temperature and hold it up against a lighted background. Check for light visible between the valve and the valve seat. If light is visible, replace the water thermostat. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 3536 Thermostat: Service and Repair REMOVAL 1. Partially drain the cooling system. 2. Disconnect the upper radiator hose. a. Compress and position the constant tension clamp. b. Disconnect the hose and position aside. 3. Remove the upper radiator hose. 4. Remove the water outlet connection. a. Remove the bolts. b. Remove the water outlet connection. 5. Remove the (A) water thermostat and the (B) O-ring. Discard the (B) O-ring. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 3537 1. Use a new (A) O-ring and position the (B) water thermostat in the (C) upper intake manifold. 2. Install the water outlet connection. a. Position the (A) water outlet connection on the (B) upper intake manifold. b. Install the bolts. 3. Connect the upper radiator hose. a. Position the hose. b. Compress and position the constant tension clamp. NOTE: Ensure that the hose is seated in the upper hose bracket. 4. Fill the cooling system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Drive Pulley, Water Pump > Component Information > Specifications Drive Pulley: Specifications DRIVE RATIO Pump Pulley Ratio ............................................................................................................................... ......................................................................... 1.3 TORQUE SPECIFICATIONS Water Pump Pulley Bolts ........................................................................................................................................................ 20-30 Nm (14.7-22 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > Customer Interest for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise Catalyst Shield: Customer Interest Exhaust System - Buzzing/Rattling Noise Article No. 98-20-10 10/12/98 ^ EXHAUST SYSTEM - LOOSE CATALYST OR MUFFLER HEAT SHIELDS ^ NOISE - "BUZZING" OR "RATTLING" - LOOSE CATALYST OR MUFFLER HEAT SHIELDS FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-99 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-99 CONTOUR LINCOLN-MERCURY: 1993-94 CAPRI, TOPAZ 1993-99 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 F SUPER DUTY, F-35O 1993-99 AEROSTAR, ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER, VILLAGER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES This TSB article is being republished in its entirety to include additional vehicles and to include 1999 model year vehicles. ISSUE A "buzzing" or "rattling" noise from the exhaust system may be caused by a loose heat shield attachment to the catalytic converter, catalytic pipes, muffler pipes and/or muffler. The noise is noticeable during normal driving conditions or at engine idle. ACTION Install worm clamps to secure loose heat shield attachments. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect for loose shields. If shield(s) is missing, this TSB does not apply. Refer to the appropriate Service or Workshop Manual for repair procedures NOTE UNDER NO CIRCUMSTANCES SHOULD A HEAT SHIELD BE REMOVED WITHOUT REPLACEMENT BEFORE THE VEHICLE IS RETURNED TO THE CUSTOMER. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > Customer Interest for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 3552 2. Install worm clamps to the catalytic converter, catalytic pipes, muffler pipes or muffler as shown in Figure 1 for the typical light truck and Figure 2 for the typical passenger car. 3. Align the clamps to secure the heat shield to the catalytic converter, catalytic pipes, muffler pipes or muffler as required. 4. Tighten the clamps to 6.8 N.m (60 lb-in). 5. Trim the excess "ear" of the clamp to approximately 2.54 cm (1"). PART NUMBER PART NAME FOTZ-5A231-A Worm clamp (4-1/2" To 9-1/2") W705949-S300 Worm clamp (3/4" To 4") OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-6-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models Bumper To Bumper Warranty Coverage For 1992-99 Models, And Any Applicable Emissions Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > Customer Interest for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 3553 OPERATION DESCRIPTION TIME 982010A Install One (1), Two (2), Or 0.3 Hr. Four (4) Worm Clamps DEALER CODING CONDITION BASIC PART NO. CODE 5E258 33 OASIS CODES: 403000, 702000, 702100, 702200, 703000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise Catalyst Shield: All Technical Service Bulletins Exhaust System - Buzzing/Rattling Noise Article No. 98-20-10 10/12/98 ^ EXHAUST SYSTEM - LOOSE CATALYST OR MUFFLER HEAT SHIELDS ^ NOISE - "BUZZING" OR "RATTLING" - LOOSE CATALYST OR MUFFLER HEAT SHIELDS FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-99 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-99 CONTOUR LINCOLN-MERCURY: 1993-94 CAPRI, TOPAZ 1993-99 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 F SUPER DUTY, F-35O 1993-99 AEROSTAR, ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER, VILLAGER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES This TSB article is being republished in its entirety to include additional vehicles and to include 1999 model year vehicles. ISSUE A "buzzing" or "rattling" noise from the exhaust system may be caused by a loose heat shield attachment to the catalytic converter, catalytic pipes, muffler pipes and/or muffler. The noise is noticeable during normal driving conditions or at engine idle. ACTION Install worm clamps to secure loose heat shield attachments. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect for loose shields. If shield(s) is missing, this TSB does not apply. Refer to the appropriate Service or Workshop Manual for repair procedures NOTE UNDER NO CIRCUMSTANCES SHOULD A HEAT SHIELD BE REMOVED WITHOUT REPLACEMENT BEFORE THE VEHICLE IS RETURNED TO THE CUSTOMER. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 3559 2. Install worm clamps to the catalytic converter, catalytic pipes, muffler pipes or muffler as shown in Figure 1 for the typical light truck and Figure 2 for the typical passenger car. 3. Align the clamps to secure the heat shield to the catalytic converter, catalytic pipes, muffler pipes or muffler as required. 4. Tighten the clamps to 6.8 N.m (60 lb-in). 5. Trim the excess "ear" of the clamp to approximately 2.54 cm (1"). PART NUMBER PART NAME FOTZ-5A231-A Worm clamp (4-1/2" To 9-1/2") W705949-S300 Worm clamp (3/4" To 4") OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-6-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models Bumper To Bumper Warranty Coverage For 1992-99 Models, And Any Applicable Emissions Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 3560 OPERATION DESCRIPTION TIME 982010A Install One (1), Two (2), Or 0.3 Hr. Four (4) Worm Clamps DEALER CODING CONDITION BASIC PART NO. CODE 5E258 33 OASIS CODES: 403000, 702000, 702100, 702200, 703000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > Page 3561 Catalyst Shield: Specifications Heat Shield Screws 13-17 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications NOTE: Tighten the manifold hardware in the sequence shown. TORQUE SPECIFICATIONS To Cylinder Head Nuts: 23-27 Nm (17-19 ft. lbs.) To Converter Nuts: 34-46 Nm (25.7-33 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 3565 Exhaust Manifold: Testing and Inspection Place a straightedge across the exhaust manifold flanges and check for warping with a feeler gauge. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Left Side Exhaust Manifold: Service and Repair Left Side REMOVAL 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Remove the front fender splash shield. ^ Remove the five screws. ^ Remove the three pushpins. 3. Remove the (A) brake booster vacuum hose bracket nut and the (B) brake booster vacuum hose bracket. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Left Side > Page 3568 4. Disconnect the EGR connections: ^ Two differential pressure feedback EGR transducer hoses (B). ^ EGR valve to exhaust manifold tube upper fitting (A). EGR valve to exhaust manifold tube lower fitting and remove the EGR exhaust tube (C). 5. Remove the three way catalytic converter to exhaust manifold nuts. 6. Remove the eight (A) exhaust manifold nuts and the (B) exhaust manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Left Side > Page 3569 7. Remove the exhaust manifold gasket. 8. Clean and inspect the exhaust manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Left Side > Page 3570 INSTALLATION To install, reverse the removal procedure. Tighten nuts in the sequence shown. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Left Side > Page 3571 Exhaust Manifold: Service and Repair Right Side REMOVAL 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Remove the front fender splash shield. ^ Remove the five screws. ^ Remove the three pushpins. 3. Remove the three way catalytic converter to exhaust manifold nuts. 4. Remove the eight (A) exhaust manifold nuts and the (B) exhaust manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Left Side > Page 3572 5. Remove and discard the exhaust manifold gasket. 6. Clean and inspect the exhaust manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Left Side > Page 3573 INSTALLATION To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Pipe: > 98-25-21 > Dec > 98 > Exhaust System Cracks/Breaks Between Muffler/Tailpipe Exhaust Pipe: Customer Interest Exhaust System - Cracks/Breaks Between Muffler/Tailpipe Article No. 98-25-21 12/21/98 EXHAUST SYSTEM - CRACK OR BREAK BETWEEN MUFFLER AND TAILPIPE - VEHICLES WITH 5.4L ENGINE AND 4X4, OR VEHICLES WITH 4.6L ENGINE AND NON-AIR SUSPENSION LIGHT TRUCK: 1997-99 EXPEDITION ISSUE Breakage of the exhaust system between the muffler and tailpipe may occur on some vehicles. This may be due to the double cardan driveshaft mass causing a resonant frequency that fatigues the exhaust system between the muffler and tailpipe. ACTION Replace the double cardan driveshaft with a new heavy duty single cardan driveshaft. Then replace broken exhaust system. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Replace the double cardan driveshaft with a new Heavy Duty Single Cardan Driveshaft (XL1Z-4602-AA - 5.4L engine or XL1Z-4602-BA - 4.6L engine) by referring to the appropriate year Expedition Workshop Manual, Section 205-01. Be sure to align paint mark on driveshaft to paint mark on axle flange. This is necessary to avoid driveline vibration. 2. Replace the muffler and tailpipe assembly by referring to the Workshop Manual, Section 309-00. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982521A Replace Driveshaft, 0.7 Hr. Muffler, And Tailpipe DEALER CODING CONDITION BASIC PART NO. CODE 4602 D9 OASIS CODES: 403000, 702000, 702200, 703000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe: > 98-25-21 > Dec > 98 > Exhaust System Cracks/Breaks Between Muffler/Tailpipe Exhaust Pipe: All Technical Service Bulletins Exhaust System - Cracks/Breaks Between Muffler/Tailpipe Article No. 98-25-21 12/21/98 EXHAUST SYSTEM - CRACK OR BREAK BETWEEN MUFFLER AND TAILPIPE - VEHICLES WITH 5.4L ENGINE AND 4X4, OR VEHICLES WITH 4.6L ENGINE AND NON-AIR SUSPENSION LIGHT TRUCK: 1997-99 EXPEDITION ISSUE Breakage of the exhaust system between the muffler and tailpipe may occur on some vehicles. This may be due to the double cardan driveshaft mass causing a resonant frequency that fatigues the exhaust system between the muffler and tailpipe. ACTION Replace the double cardan driveshaft with a new heavy duty single cardan driveshaft. Then replace broken exhaust system. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Replace the double cardan driveshaft with a new Heavy Duty Single Cardan Driveshaft (XL1Z-4602-AA - 5.4L engine or XL1Z-4602-BA - 4.6L engine) by referring to the appropriate year Expedition Workshop Manual, Section 205-01. Be sure to align paint mark on driveshaft to paint mark on axle flange. This is necessary to avoid driveline vibration. 2. Replace the muffler and tailpipe assembly by referring to the Workshop Manual, Section 309-00. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982521A Replace Driveshaft, 0.7 Hr. Muffler, And Tailpipe DEALER CODING CONDITION BASIC PART NO. CODE 4602 D9 OASIS CODES: 403000, 702000, 702200, 703000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 98-20-10 > Oct > 98 > Exhaust System Buzzing/Rattling Noise Heat Shield: Customer Interest Exhaust System - Buzzing/Rattling Noise Article No. 98-20-10 10/12/98 ^ EXHAUST SYSTEM - LOOSE CATALYST OR MUFFLER HEAT SHIELDS ^ NOISE - "BUZZING" OR "RATTLING" - LOOSE CATALYST OR MUFFLER HEAT SHIELDS FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-99 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-99 CONTOUR LINCOLN-MERCURY: 1993-94 CAPRI, TOPAZ 1993-99 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 F SUPER DUTY, F-35O 1993-99 AEROSTAR, ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER, VILLAGER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES This TSB article is being republished in its entirety to include additional vehicles and to include 1999 model year vehicles. ISSUE A "buzzing" or "rattling" noise from the exhaust system may be caused by a loose heat shield attachment to the catalytic converter, catalytic pipes, muffler pipes and/or muffler. The noise is noticeable during normal driving conditions or at engine idle. ACTION Install worm clamps to secure loose heat shield attachments. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect for loose shields. If shield(s) is missing, this TSB does not apply. Refer to the appropriate Service or Workshop Manual for repair procedures NOTE UNDER NO CIRCUMSTANCES SHOULD A HEAT SHIELD BE REMOVED WITHOUT REPLACEMENT BEFORE THE VEHICLE IS RETURNED TO THE CUSTOMER. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 98-20-10 > Oct > 98 > Exhaust System Buzzing/Rattling Noise > Page 3595 2. Install worm clamps to the catalytic converter, catalytic pipes, muffler pipes or muffler as shown in Figure 1 for the typical light truck and Figure 2 for the typical passenger car. 3. Align the clamps to secure the heat shield to the catalytic converter, catalytic pipes, muffler pipes or muffler as required. 4. Tighten the clamps to 6.8 N.m (60 lb-in). 5. Trim the excess "ear" of the clamp to approximately 2.54 cm (1"). PART NUMBER PART NAME FOTZ-5A231-A Worm clamp (4-1/2" To 9-1/2") W705949-S300 Worm clamp (3/4" To 4") OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-6-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models Bumper To Bumper Warranty Coverage For 1992-99 Models, And Any Applicable Emissions Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 98-20-10 > Oct > 98 > Exhaust System Buzzing/Rattling Noise > Page 3596 OPERATION DESCRIPTION TIME 982010A Install One (1), Two (2), Or 0.3 Hr. Four (4) Worm Clamps DEALER CODING CONDITION BASIC PART NO. CODE 5E258 33 OASIS CODES: 403000, 702000, 702100, 702200, 703000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise Heat Shield: All Technical Service Bulletins Exhaust System - Buzzing/Rattling Noise Article No. 98-20-10 10/12/98 ^ EXHAUST SYSTEM - LOOSE CATALYST OR MUFFLER HEAT SHIELDS ^ NOISE - "BUZZING" OR "RATTLING" - LOOSE CATALYST OR MUFFLER HEAT SHIELDS FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-99 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-99 CONTOUR LINCOLN-MERCURY: 1993-94 CAPRI, TOPAZ 1993-99 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 F SUPER DUTY, F-35O 1993-99 AEROSTAR, ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER, VILLAGER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES This TSB article is being republished in its entirety to include additional vehicles and to include 1999 model year vehicles. ISSUE A "buzzing" or "rattling" noise from the exhaust system may be caused by a loose heat shield attachment to the catalytic converter, catalytic pipes, muffler pipes and/or muffler. The noise is noticeable during normal driving conditions or at engine idle. ACTION Install worm clamps to secure loose heat shield attachments. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect for loose shields. If shield(s) is missing, this TSB does not apply. Refer to the appropriate Service or Workshop Manual for repair procedures NOTE UNDER NO CIRCUMSTANCES SHOULD A HEAT SHIELD BE REMOVED WITHOUT REPLACEMENT BEFORE THE VEHICLE IS RETURNED TO THE CUSTOMER. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 3602 2. Install worm clamps to the catalytic converter, catalytic pipes, muffler pipes or muffler as shown in Figure 1 for the typical light truck and Figure 2 for the typical passenger car. 3. Align the clamps to secure the heat shield to the catalytic converter, catalytic pipes, muffler pipes or muffler as required. 4. Tighten the clamps to 6.8 N.m (60 lb-in). 5. Trim the excess "ear" of the clamp to approximately 2.54 cm (1"). PART NUMBER PART NAME FOTZ-5A231-A Worm clamp (4-1/2" To 9-1/2") W705949-S300 Worm clamp (3/4" To 4") OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-6-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models Bumper To Bumper Warranty Coverage For 1992-99 Models, And Any Applicable Emissions Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 3603 OPERATION DESCRIPTION TIME 982010A Install One (1), Two (2), Or 0.3 Hr. Four (4) Worm Clamps DEALER CODING CONDITION BASIC PART NO. CODE 5E258 33 OASIS CODES: 403000, 702000, 702100, 702200, 703000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Customer Interest for Muffler: > 98-25-21 > Dec > 98 > Exhaust System - Cracks/Breaks Between Muffler/Tailpipe Muffler: Customer Interest Exhaust System - Cracks/Breaks Between Muffler/Tailpipe Article No. 98-25-21 12/21/98 EXHAUST SYSTEM - CRACK OR BREAK BETWEEN MUFFLER AND TAILPIPE - VEHICLES WITH 5.4L ENGINE AND 4X4, OR VEHICLES WITH 4.6L ENGINE AND NON-AIR SUSPENSION LIGHT TRUCK: 1997-99 EXPEDITION ISSUE Breakage of the exhaust system between the muffler and tailpipe may occur on some vehicles. This may be due to the double cardan driveshaft mass causing a resonant frequency that fatigues the exhaust system between the muffler and tailpipe. ACTION Replace the double cardan driveshaft with a new heavy duty single cardan driveshaft. Then replace broken exhaust system. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Replace the double cardan driveshaft with a new Heavy Duty Single Cardan Driveshaft (XL1Z-4602-AA - 5.4L engine or XL1Z-4602-BA - 4.6L engine) by referring to the appropriate year Expedition Workshop Manual, Section 205-01. Be sure to align paint mark on driveshaft to paint mark on axle flange. This is necessary to avoid driveline vibration. 2. Replace the muffler and tailpipe assembly by referring to the Workshop Manual, Section 309-00. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982521A Replace Driveshaft, 0.7 Hr. Muffler, And Tailpipe DEALER CODING CONDITION BASIC PART NO. CODE 4602 D9 OASIS CODES: 403000, 702000, 702200, 703000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Muffler: > 98-25-21 > Dec > 98 > Exhaust System - Cracks/Breaks Between Muffler/Tailpipe Muffler: All Technical Service Bulletins Exhaust System - Cracks/Breaks Between Muffler/Tailpipe Article No. 98-25-21 12/21/98 EXHAUST SYSTEM - CRACK OR BREAK BETWEEN MUFFLER AND TAILPIPE - VEHICLES WITH 5.4L ENGINE AND 4X4, OR VEHICLES WITH 4.6L ENGINE AND NON-AIR SUSPENSION LIGHT TRUCK: 1997-99 EXPEDITION ISSUE Breakage of the exhaust system between the muffler and tailpipe may occur on some vehicles. This may be due to the double cardan driveshaft mass causing a resonant frequency that fatigues the exhaust system between the muffler and tailpipe. ACTION Replace the double cardan driveshaft with a new heavy duty single cardan driveshaft. Then replace broken exhaust system. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Replace the double cardan driveshaft with a new Heavy Duty Single Cardan Driveshaft (XL1Z-4602-AA - 5.4L engine or XL1Z-4602-BA - 4.6L engine) by referring to the appropriate year Expedition Workshop Manual, Section 205-01. Be sure to align paint mark on driveshaft to paint mark on axle flange. This is necessary to avoid driveline vibration. 2. Replace the muffler and tailpipe assembly by referring to the Workshop Manual, Section 309-00. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982521A Replace Driveshaft, 0.7 Hr. Muffler, And Tailpipe DEALER CODING CONDITION BASIC PART NO. CODE 4602 D9 OASIS CODES: 403000, 702000, 702200, 703000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures Engine Control Module: Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 3624 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 3625 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 3626 Engine Control Module: Technical Service Bulletins PCM - Reprogramming Out of Vehicle Article No. 99-4-3 03/08/99 REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V VEHICLES ONLY FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97 PROBE 1996-99 CONTOUR, ESCORT, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to update the affected vehicles and to include an Application Chart for the affected vehicles. ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain reasonably priced, timely PCM programming services at dealerships. Ford has released an out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are reprogrammable to update calibration levels or to reprogram a common hardware type to a new calibration in order to fill a service need without ordering a new PCM. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 3627 ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to have modules updated to new calibrations through the Parts Department instead of ordering new parts. Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the module. An aftermarket service center may bring a module to a dealership for a calibration update or may request an updated calibration be installed to a new service part. The EPA regulations require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a calibration on a PCM out of the vehicle. The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector. The proper calibration must be downloaded to the Data Transfer Card through Service Bay Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is connected, follow the calibration download instructions displayed on the NGS screen. The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling 1-800-ROTUNDA. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-26-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 206000, 290000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 3628 Engine Control Module: Technical Service Bulletins PCM - Reprogramming Tips Article No. 97-9-8 04/28/97 POWERTRAIN CONTROL MODULE - REPROGRAM POWERTRAIN CONTROL MODULE (PCM) - SERVICE PROCEDURES - SERVICE TIP FORD: 1994-97 CROWN VICTORIA, MUSTANG, THUNDERBIRD 1996-97 CONTOUR, ESCORT, PROBE, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR, GRAND MARQUIS 1995-97 CONTINENTAL, TOWN CAR 1996-97 MARK VIII, MYSTIQUE, SABLE, TRACER LIGHT TRUCK: 1994-97 ECONOLINE, F-150-350 SERIES 1995-97 RANGER 1995-98 WINDSTAR 1996 BRONCO 1996-97 AEROSTAR, EXPLORER 1997 EXPEDITION, MOUNTAINEER This TSB article is being republished in its entirety to include Windstar. ISSUE: Powertrain Control Modules (PCMs) no longer need to be replaced when servicing driveability concerns. The only time a PCM needs replacing is when it can no longer be reprogrammed and/or is damaged. In all other cases, the PCM must be reprogrammed and NOT REPLACED. ACTION: Use the following Service Procedure to properly reprogram a PCM. SERVICE PROCEDURE PCM REPROGRAMMING USING SBDS 1. At the Main menu, select Powertrain and enter the Vehicle Identification Number (VIN). Select "Continue." 2. From the Powertrain menu, select Electronic Engine category. 3. Scroll through the "Tool List" to PCM Reprogramming and select "Continue." 4. Any TSBs or Recalls for the entered vehicle will be displayed. There is up to a 6 week delay for TSB/Recall information updates on SBDS. New TSBs/Recalls may not appear or only the TSB number will be displayed even though the new calibration is on the current calibration CD-ROM. Also, if the vehicle calibration is being updated because of a Special Service Message, Broadcast Message or the PCM was replaced and requires calibration, no screen may appear. This is not a concern and will not prevent programming updates or being paid for programming updates. 5. Follow all hook-up instructions and continue as prompted to the calibration screen. Typically, a list of calibration numbers will appear. Answer as appropriate for the vehicle and select "Continue." SBDS will then validate the information entered against the information read in the PCM, and any mismatch of software or hardware will be displayed for technician action. 6. Insert the proper calibration or the latest level CD-ROM when prompted and follow the instructions as displayed by SBDS. Do not crank the engine. SBDS will update the engine calibration to the latest level calibration for the selected calibration. 7. After programming is complete, SBDS will display a representation of the Authorized Modification Decal with the Engineering Part Number for the PCM installed. It is important that the label be completed and attached to the vehicle. S8DS will also automatically print a copy of the vehicle log for filing with the Repair Order. 8. Selecting "Continue" will call for a KOEO self test. Any hard faults present after performing self test were not caused by reprogramming. The calibration has now been validated and the PCM is operating properly. Unless directed by other Service Procedures, the vehicle can be released to Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 3629 the customer. PCM REPROGRAMMING WITH SBTS/NGS 1. Select "NGS," then follow procedure "Touring PLM Recalibration." 2. Be sure to use cable with oversized DCL connector. The oversized connector incorporates an 18-volt transformer supplying the required voltage to reprogram the PCM. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-25-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3630 Engine Control Module: Specifications Powertrain Control Module Electrical Connector Bolt 5-7 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3631 Engine Control Module: Locations Engine View The Powertrain Control Module is located at right side of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3634 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3635 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3636 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3637 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3638 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3639 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3640 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3641 Engine Control Module: Connector Views Powertrain Control Module (Part 1 Of 3) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3642 Powertrain Control Module (Part 2 Of 3) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3643 Powertrain Control Module (Part 3 Of 3) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service Precautions > Electronic Component Handling Engine Control Module: Service Precautions Electronic Component Handling STATIC DISCHARGE - Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. - Never touch the PCM connector pins, integrated circuit connector pins, or soldered components on the PCM circuit board. TESTING - When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. - To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE - Do not try to disassemble the control unit. - Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, PCM and radio. - If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECUs. - Avoid getting water on any of the Fuel and Engine Control System Components. Never apply battery power to a component unless directed to do so in a test procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service Precautions > Electronic Component Handling > Page 3646 Engine Control Module: Service Precautions Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. PCM memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service Precautions > Electronic Component Handling > Page 3647 Engine Control Module: Service Precautions Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service Precautions > Page 3648 Engine Control Module: Description and Operation OVERVIEW The Electronic Engine Control (EEC) system provides optimum control of the engine and transmission through the enhanced capability of the Powertrain Control Module (PCM). The EEC system also has an On-board Diagnostics (OBDII) monitoring system with features and functions to meet federal regulations on exhaust emissions. COMPONENTS The EEC system has two major divisions: hardware and software. The hardware includes the PCM, Natural Gas Vehicle (NGV) Module, Constant Control Relay Module (CCRM), Variable Load Control Module (VLCM), sensors, switches, actuators, solenoids, and interconnecting terminals. The software in the PCM provides the strategy control for outputs (engine hardware) based on the values of the inputs to the PCM. OPERATION The PCM receives information from a variety of sensor and switch inputs. Based on the strategy and calibration stored within the memory chip, the PCM generates the appropriate output. The system is designed to minimize emissions and optimize fuel economy and driveability. The software strategy controls the basic operation of the engine and transmission, provides the OBD II strategy, controls the Malfunction Indicator Lamp (MIL), communicates to the scan tool [New Generation Star (NGS), etc.] via the Data Link Connector (DLC), allows for Flash Electrically Erasable/ Programmable Read Only Memory (FEEPROM), provides idle air and fuel trim, and controls Failure Mode Effects Management (FMEM). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Reset Procedure Engine Control Module: Reset Procedure Description The Powertrain Control Module (PCM) Reset allows the scan tool to command the PCM to clear all emission-related diagnostic information. When resetting the PCM, a DTC P1000 will be stored in the PCM until all the OBD II system monitors or components have been tested to satisfy a drive cycle, without any other faults occurring. The following events occur when a PCM reset is performed: - Clears the number of Diagnostic Trouble Codes (DTCs). - Clears the DTCs. - Clears the freeze frame data. - Clears oxygen sensor test data. - Resets status of the OBD II system monitors. - Sets DTC P1000. New Generation STAR (NGS) and Generic Scan Tool Refer to the manufacturer's manual for specific instructions on how to perform PCM reset. Resetting Keep Alive Random Access Memory (RAM) Disconnect the battery ground cable for a minimum of 5 minutes. Resetting Keep Alive RAM will clear learned values the PCM has stored for adaptive systems such as idle and fuel trim. After Keep Alive RAM has been reset, the vehicle may exhibit certain driveability concerns. It will be necessary to drive the vehicle to allow the PCM to relearn values for optimum driveability and performance. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Reset Procedure > Page 3651 Engine Control Module: Removal and Replacement REMOVAL 1. Remove the battery and battery tray. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Loosen the PCM electrical connector bolt and separate the PCM electrical connectors. 3. Remove the RH front door scuff plate. 4. Remove the RH cowl side trim panel. 5. Release the PCM bracket clip. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Reset Procedure > Page 3652 6. Remove the PCM. INSTALLATION To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3656 Power Distribution Box The Powertrain Control Module (EEC) Power Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3661 Power Distribution Box The Fuel Pump Relay is located in the LH front of engine compartment, in the Power Distribution box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3665 Power Distribution Box The Powertrain Control Module (EEC) Power Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations Ignition Control Module: Locations The ignition control module is integrated within the powertrain control module. It is not a separately replaceable component. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 3670 Ignition Control Module: Description and Operation PURPOSE - The Ignition Control Module (ICM) is incorporated within the Powertrain Control Module (PCM). The ICM receives engine position and speed information from within the crankshaft position sensor and desired spark advance information from the PCM. OPERATION - The ICM synthesizes a profile ignition pick up signal and ignition diagnostic monitor signal for use within The PCM. - The PCM uses this information to determine which ignition coil to fire, calculating the turn ON/OFF times of the ignition coil required to achieve the correct dwell and spark advance. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3681 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3682 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3688 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3689 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor Assembly Replacement Air Flow Meter/Sensor: All Technical Service Bulletins Mass Air Flow Sensor - Assembly Replacement Article No. 96-22-5 10/21/96 MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP FORD: 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR, EXPLORER, RANGER 1993-97 VILLAGER 1994-96 BRONCO 1994-97 ECONOLINE 1995-97 F-150, WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: The Mass Air Flow (MAF) sensor is not designed to be removed from its body (die-cast or plastic) for servicing. The sensing elements located inside the by-pass tube can be damaged by poking/probing/touching. ACTION: Service the MAF sensor as an assembly (refer to Figure 1). WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor Assembly Replacement > Page 3694 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement Air Flow Meter/Sensor: All Technical Service Bulletins Mass Air Flow Sensor - Assembly Replacement Article No. 96-22-5 10/21/96 MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP FORD: 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR, EXPLORER, RANGER 1993-97 VILLAGER 1994-96 BRONCO 1994-97 ECONOLINE 1995-97 F-150, WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: The Mass Air Flow (MAF) sensor is not designed to be removed from its body (die-cast or plastic) for servicing. The sensing elements located inside the by-pass tube can be damaged by poking/probing/touching. ACTION: Service the MAF sensor as an assembly (refer to Figure 1). WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement > Page 3700 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3701 Air Flow Meter/Sensor: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3702 RH Component The Mass Air Flow Sensor is located in air cleaner assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3703 Air Flow Meter/Sensor: Description and Operation PURPOSE The Mass Air Flow (MAF) sensor: - Sends the PCM a signal indicating mass airflow rate of air entering the engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal Air Flow Meter/Sensor: Service and Repair Removal REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Open the engine air cleaner. - Disconnect the Mass Air Flow (MAF) sensor connector from the wiring harness. - Release the air cleaner clamp. Separate the inlet side of the air cleaner from the outlet side of the air cleaner. 3. Cut the tape on the wire loom of the extension harness. CAUTION: Do not cut the MAF sensor wires when cutting the tape on the wire loom. - Peel back the wire loom from the extension harness near the grommet in the air cleaner. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal > Page 3706 4. Remove the grommet from the outlet side of the air cleaner and slide the grommet down the extension harness. 5. Remove the MAF sensor plate and MAF sensor from the outlet side of the engine air cleaner. 6. Disconnect the MAF sensor electrical connector. 7. Remove the nuts and separate the MAF plate from the MAF sensor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal > Page 3707 Air Flow Meter/Sensor: Service and Repair Installation INSTALLATION CAUTION: - Do not tamper with the MAF sensing elements located in the airflow bypass; tampering may result in unit failure. - The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. NOTE: - Use the alignment notch to properly align the inlet side and the outlet side of the engine air cleaner. - The MAF sensor module and body are calibrated and replaced as a unit. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt 8-12 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3711 Camshaft Position Sensor: Locations Engine View The Camshaft Position Sensor is located in front of the engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3712 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3713 Camshaft Position Sensor: Description and Operation The Camshaft Position (CMP) sensor: - Sends the PCM a signal indicating camshaft position, which is used for fuel synchronization. NOTE: The Camshaft Position (CMP) sensor is also referred to as Cylinder Identification Sensor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3714 Camshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the CMP sensor. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Coolant Temperature Sensor Coolant Temperature Sensor/Switch (For Computer): Locations Coolant Temperature Sensor Engine View The Engine Coolant Temperature Sensor is located in front of the engine. NOTE: In some applications of the 4.6L engine, the Cylinder Head Temperature (CHT) sensor provides the signal used by the Powertrain Control Module (PCM) in place of the Coolant Temperature Sensor (CTS) for functions such as, but not limited to, activating the electric cooling fans. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Coolant Temperature Sensor > Page 3719 Engine Views Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3720 Coolant Temperature Sensor/Switch (For Computer): Description and Operation The Engine Coolant Temperature (ECT) sensor: - Sends the PCM a signal indicating engine temperature. - Resistance decreases as coolant temperature increases. NOTE: In some applications of the 4.6L engine, the Cylinder Head Temperature (CHT) sensor provides the signal used by the Powertrain Control Module (PCM) in place of the Coolant Temperature Sensor (CTS) for functions such as, but not limited to, activating the electric cooling fans. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3721 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Partially drain the cooling system. 3. Remove the Engine Coolant Temperature (ECT) sensor . 1 Disconnect the electrical connector. 2 Remove the ECT sensor. INSTALLATION 1. Install the ECT. 2. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Retainer Torque 8-12 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3725 Crankshaft Position Sensor: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3726 The Crankshaft Position Sensor is located at the lower front of engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3727 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) sensor: - Sends the PCM a signal indicating crankshaft position. - Is essential for calculating spark timing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3728 Crankshaft Position Sensor: Service and Repair REMOVAL WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 3. Release the tension on the accessory drive belt. 1. Remove the A/C compressor. 1 Remove the A/C compressor bolts. 2 Remove the A/C compressor and position aside. NOTE: Do not remove lines from the A/C compressor. 5. Remove the (A) CKP sensor bolt and the (B) CKP sensor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3729 To install, reverse the removal procedure NOTE:If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications Engine Temperature Sensor: Specifications Cylinder Head Temperature (CHT) Sensor 25 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 3733 Engine Temperature Sensor: Locations Engine View The Cylinder Head Temperature Sensor is located at top front of the engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 3734 Engine Temperature Sensor: Description and Operation FEATURES The Cylinder Head Temperature (CHT) sensor: - Is mounted into the wall of the cylinder head and is not connected to any coolant passages. Sends a signal to the PCM indicating the cylinder head temperature. - If the temperature exceeds: 130°C (265°F) the PCM disables four fuel injectors at a time. The PCM will alternate which four injectors are disabled every 32 engine cycles. The four cylinders that are not being fuel injected act as air pumps to aid in cooling the engine. - If the temperature exceeds: 166°C (330°F) the PCM disables all of the fuel injectors until the engine temperature drops below: 153°C (308°F) - If the engine reaches critical temperature, the following happens: - The coolant temperature gauge pointer will read fully hot at 121°C (250°F). - The check gauge warning indicator will illuminate. - DTCs are set. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 3735 Engine Temperature Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the Cylinder Head Temperature (CHT) sensor. 1 Disconnect the electrical connector. 2 Remove the CHT sensor. INSTALLATION 1. Install the CHT. 2. Install the intake manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure (FTP) Sensor PURPOSE The Fuel Tank Pressure (FTP) sensor (A) is used to monitor the fuel tank pressure or vacuum during the OBD II purge monitor test of the Evaporative Emission System for Running Loss vehicles (passenger cars with fuel vapor control valves and trucks with fuel vapor valves). This monitor also performs a fuel system integrity check to determine if there is an evaporative emission system leak. Variations in pressure will be converted into an analog voltage input signal to the PCM. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3742 Engine View The Intake Air Temperature Sensor is located on the air intake tube. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3743 Intake Air Temperature Sensor: Description and Operation PURPOSE The Intake Air Temperature (IAT) sensor: - Sends the PCM a signal indicating the temperature of the air entering the engine. - It's resistance decreases as temperature increases. - The PCM uses the air temperature information as a correction factor in the calculation of fuel, spark and MAF. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3744 Intake Air Temperature Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 3. Remove the IAT sensor. INSTALLATION To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor 20-27 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 3748 Knock Sensor: Description and Operation The knock sensor is located in the lifter valley and: - Sends a signal to the PCM indicating engine detonation. - If detonation is occurring, the PCM then changes engine timing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 3749 Knock Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the Knock Sensor (KS) . 1 Disconnect the electrical connector. 2 Remove the KS. INSTALLATION 1. Install the Knock Sensor (KS) 1 Install the KS. 2 Connect the electrical connector. 2. Install the intake manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns Oxygen Sensor: Customer Interest PCM - MIL ON/Multiple DTC's Set/Driveability Concerns Article No. 97-26-19 12/22/97 ^ HESITATION/SURGE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ MALFUNCTION INDICATOR LAMP (MIL) - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 ^ ROUGH IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ STALL - LOW SPEEDS AND OR IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 F-350, NAVIGATOR This TSB article is being republished in its entirety to correct the PCM Application Chart and include a reference to TSB 97-26-17. CALIBRATION: 7-46D-R07, 7-46E-R07, 7-46F-R07, 7-46R-R07, 7-46T-R07, 7-46U-R07, 7-46F-R10, 7-46U-R10, 7-48J-R05, 7-48U-R05, 7-48J-R10, 7-48U-R10, 8-46D-R05, 8-46E-R05, 8-46F-R05, 8-46R-RO5, 8-46T-R05, 8-46U-R05, 8-48J-R05 WARNING: THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS. ISSUE: The Malfunction Indicator Lamp (MIL) may illuminate on vehicles with a 4.6L or 5.4L engine, and one or more of the following concerns may be present: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 3758 ^ MIL lamp on with Diagnostic Trouble Codes (DTCs): P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 ^ Rough idle ^ Engine miss ^ Hesitation/Surge ^ Buck/Jerk ^ Stall at idle ^ Near stall ^ Stall at low speeds This may be caused by the Heated Exhaust Gas Oxygen (HEGO) monitor calibration not allowing enough time for proper monitoring. ACTION: Reprogram the Powertrain Control Module (PCM) and replace the HEGO sensor(s). Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal diagnostics as outlined in the 1997 Powertrain Control/Emissions Diagnosis (PC/ED) On-Board Diagnostics II (OBD-II) Service Manual and repair as required. 2. If the concern still exists or no problems were found, reprogram the PCM using Service Bay Diagnostic System (SDBS) or New Generation Star (NGS) Tester. Refer to the following Recalibration Cross Reference Chart for correct PCM calibration. 3. Replace the HEGO sensor(s) (F88z-9F472-AB) as required. NOTE: FOR 5.4L APPLICATIONS, DEALERS MUST ALSO PERFORM TSB 97-26-17 TO INSTALL THE DRAIN TUBE ON THE LOWER A/C EVAPORATOR DRAIN. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 3759 NOTE: PCM REPLACEMENT IS NOT AUTHORIZED BY THIS TSB. REFER TO THE POWERTRAIN CONTROL/EMISSIONS DIAGNOSIS (PC/ED) SERVICE MANUAL FOR APPROPRIATE DIAGNOSTIC PROCEDURES IF PCM HARDWARE CONCERNS EXIST. Obtain an Authorized Modification Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME F88Z-9F472-AB Heated Exhaust Gas Oxygen (HEGO) Sensor OTHER APPLICABLE ARTICLES: 97-26-17 SUPERSEDES: 97-21-13 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 972619A Reprogram Powertrain 0.2 Hr. Control Module (PCM) 972619DL Replace Heated Exhaust 0.3 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Left Side 972619DR Replace Heated Exhaust 0.6 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Right Side 972619DT Replace Heated Exhaust 0.8 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Both 972619ET Replace Heated Exhaust 0.4 Hr. Gas Oxygen (HEGO) Sensors - 4.6L Both 972619E Replace Heated Exhaust 0.3 Hr. Gas Oxygen (H EGO) Sensors - 4.6L One DEALER CODING CONDITION BASIC PART NO. CODE 9F472 42 OASIS CODES: 607000, 607400, 607700, 608000, 608400, Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 3760 611000, 611500, 612000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3766 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3767 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3768 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3769 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3770 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3771 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3772 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3773 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3774 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3775 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3776 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3777 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3778 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3779 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3780 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns Oxygen Sensor: All Technical Service Bulletins PCM - MIL ON/Multiple DTC's Set/Driveability Concerns Article No. 97-26-19 12/22/97 ^ HESITATION/SURGE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ MALFUNCTION INDICATOR LAMP (MIL) - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 ^ ROUGH IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ STALL - LOW SPEEDS AND OR IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 F-350, NAVIGATOR This TSB article is being republished in its entirety to correct the PCM Application Chart and include a reference to TSB 97-26-17. CALIBRATION: 7-46D-R07, 7-46E-R07, 7-46F-R07, 7-46R-R07, 7-46T-R07, 7-46U-R07, 7-46F-R10, 7-46U-R10, 7-48J-R05, 7-48U-R05, 7-48J-R10, 7-48U-R10, 8-46D-R05, 8-46E-R05, 8-46F-R05, 8-46R-RO5, 8-46T-R05, 8-46U-R05, 8-48J-R05 WARNING: THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS. ISSUE: The Malfunction Indicator Lamp (MIL) may illuminate on vehicles with a 4.6L or 5.4L engine, and one or more of the following concerns may be present: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 3785 ^ MIL lamp on with Diagnostic Trouble Codes (DTCs): P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 ^ Rough idle ^ Engine miss ^ Hesitation/Surge ^ Buck/Jerk ^ Stall at idle ^ Near stall ^ Stall at low speeds This may be caused by the Heated Exhaust Gas Oxygen (HEGO) monitor calibration not allowing enough time for proper monitoring. ACTION: Reprogram the Powertrain Control Module (PCM) and replace the HEGO sensor(s). Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal diagnostics as outlined in the 1997 Powertrain Control/Emissions Diagnosis (PC/ED) On-Board Diagnostics II (OBD-II) Service Manual and repair as required. 2. If the concern still exists or no problems were found, reprogram the PCM using Service Bay Diagnostic System (SDBS) or New Generation Star (NGS) Tester. Refer to the following Recalibration Cross Reference Chart for correct PCM calibration. 3. Replace the HEGO sensor(s) (F88z-9F472-AB) as required. NOTE: FOR 5.4L APPLICATIONS, DEALERS MUST ALSO PERFORM TSB 97-26-17 TO INSTALL THE DRAIN TUBE ON THE LOWER A/C EVAPORATOR DRAIN. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 3786 NOTE: PCM REPLACEMENT IS NOT AUTHORIZED BY THIS TSB. REFER TO THE POWERTRAIN CONTROL/EMISSIONS DIAGNOSIS (PC/ED) SERVICE MANUAL FOR APPROPRIATE DIAGNOSTIC PROCEDURES IF PCM HARDWARE CONCERNS EXIST. Obtain an Authorized Modification Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME F88Z-9F472-AB Heated Exhaust Gas Oxygen (HEGO) Sensor OTHER APPLICABLE ARTICLES: 97-26-17 SUPERSEDES: 97-21-13 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 972619A Reprogram Powertrain 0.2 Hr. Control Module (PCM) 972619DL Replace Heated Exhaust 0.3 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Left Side 972619DR Replace Heated Exhaust 0.6 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Right Side 972619DT Replace Heated Exhaust 0.8 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Both 972619ET Replace Heated Exhaust 0.4 Hr. Gas Oxygen (HEGO) Sensors - 4.6L Both 972619E Replace Heated Exhaust 0.3 Hr. Gas Oxygen (H EGO) Sensors - 4.6L One DEALER CODING CONDITION BASIC PART NO. CODE 9F472 42 OASIS CODES: 607000, 607400, 607700, 608000, 608400, Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 3787 611000, 611500, 612000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3793 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3794 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3795 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3796 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3797 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3798 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3799 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3800 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3801 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3802 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3803 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3804 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3805 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3806 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 3807 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 3808 Oxygen Sensor: Specifications Heated Oxygen Sensor 36-46 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > OBD-II Heated Oxygen Sensor Numbering Convention Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > OBD-II Heated Oxygen Sensor Numbering Convention > Page 3811 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3814 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3815 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3816 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3817 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3818 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3819 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3820 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3821 Oxygen Sensor: Connector Views Vehicle Harness Connector Connector Test Pin Numbers Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3822 HO2S Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3823 Oxygen Sensor: Description and Operation UPSTREAM HEATED OXYGEN (HO2S) SENSOR: - Has the ability to create a voltage signal dependent on exhaust oxygen content. - Provides feedback information to the PCM used to calculate fuel delivery. - Is positioned in the exhaust manifold outlet. DOWNSTREAM HEATED OXYGEN (HO2S) SENSOR: - Monitors oxygen content after the catalytic converter. - Provides a voltage to the PCM used to calculate catalytic converter integrity. - Is also referred to as the Catalyst Monitor Sensor (CMS). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Upstream Heated Oxygen Sensor Oxygen Sensor: Service and Repair Upstream Heated Oxygen Sensor REMOVAL WARNING: - The normal operating temperature of the exhaust system is very high. never attempt to service any part of the system until it has cooled. Be especially careful when working around the three way catalytic converter. The temperature of the three way catalytic converter rises to a high level after only a few minutes of engine operation. - The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by tuning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. 1. Turn the ignition key off. 2. Disconnect the two Heated Oxygen Sensor (HO2S) electrical connectors. 3. Raise and support the vehicle. 4. Use Oxygen Sensor Wrench to remove the LH and RH HO2Ss. INSTALLATION To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Upstream Heated Oxygen Sensor > Page 3826 Oxygen Sensor: Service and Repair Downstream Heated Oxygen Sensor REMOVAL WARNING: - The normal operating temperature of the exhaust system is very high. Never attempt to service any part of the system until it has cooled. Be especially careful when working around the three way catalytic converter. The temperature of the three way catalytic converter rises to a high level after only a few minutes of engine operation. - The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by tuning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. 1. Turn the ignition key off. 2. Raise and support the vehicle. 3. Remove the Catalyst Monitor Sensor (CMS). 1 Disconnect the electrical connector. 2 Use Oxygen Sensor Wrench to remove the CMS. INSTALLATION To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Page 3827 Oxygen Sensor: Tools and Equipment Oxygen Sensor Wrench T94 - P-9472-A Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision Pressure Feedback Exhaust Sensor: Technical Service Bulletins EGR DPFE Sensor - Voltage Range Revision Article No. 97-22-1 10/27/97 DELTA PRESSURE FEEDBACK EGR (DPFE) - DIAGNOSTIC TIPS FORD: 1994-97 MUSTANG, THUNDERBIRD 1995-97 CONTOUR, CROWN VICTORIA 1996-97 ESCORT, TAURUS LINCOLN-MERCURY: 1990-97 TOWN CAR 1994-97 COUGAR 1995-97 CONTINENTAL, GRAND MARQUIS, MYSTIQUE 1996-97 SABLE, TRACER LIGHT TRUCK: 1994-97 EXPLORER 1995-97 ECONOLINE, F-150-350 SERIES, WINDSTAR 1996-97 AEROSTAR 1997 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: The current DPFE sensor diagnostic reference values as published in the Powertrain Control/Emissions Diagnosis (PC/ED) Service Manual, and also accessed by either the Service Bay Diagnostic System (SBDS) or Service Bay Technical System (SBTS), can lead to the replacement of good DPFE sensors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision > Page 3832 ACTION: Use the following revised DPFE sensor voltage ranges for all (black plastic or aluminum) DPFE system applications when checking the PID (Parameter Identifier Display) value "DPFEGR" or when measuring the DPFE sensor input directly at the breakout box. Refer to Figure 1. NOTE: THESE LISTED VOLTAGE RANGES SHOULD BE USED FOR ALL (BLACK PLASTIC OR ALUMINUM) DPFE SYSTEM APPLICATIONS WHENEVER CHECKING THE PID VALUE "DPFEGR" OR WHEN MEASURING THE DPFE SENSOR INPUT DIRECTLY AT THE BREAKOUT BOX. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3833 Pressure Feedback Exhaust Sensor: Locations Engine View The Differential Pressure Feedback EGR (DPFE) Sensor is located at the right side of engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Retaining Screws 2.8-3.4 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 3837 Throttle Position Sensor: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 3838 The Throttle Position Sensor is attached to the throttle body. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 3839 Throttle Position Sensor: Description and Operation PURPOSE The Throttle Position Sensor (TP): - Sends the PCM a signal indicating the throttle plate angle. - Is the main input to the PCM from the driver. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 3840 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Remove the accelerator control splash shield. 1 Remove three accelerator splash shield bolts. 2 Remove the accelerator control splash shield from the vehicle. 3. Remove the Throttle Position (TP) sensor. 1 Disconnect the electrical connector. 2 Remove the two bolts. 3 Remove the TP sensor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 3841 To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > New Digital Transmission Range Sensor - Service Tip Transmission Position Switch/Sensor: Technical Service Bulletins New Digital Transmission Range Sensor - Service Tip Article No. 96-24-10 11/18/96 TRANSMISSION - E40D - 4R70W - 4R44E - 5R55E - NEW DIGITAL TRANSMISSION RANGE SENSOR - DIAGNOSIS SERVICE TIP LINCOLN-MERCURY: 1997 MARK VIII LIGHT TRUCK: 1997 AEROSTAR, ECONOLINE, EXPEDITION, EXPLORER, F-150, F-250, MOUNTAINEER ISSUE: Beginning with Job 1 1997, some vehicles will be equipped with a new Digital Transmission Range (DTR) sensor. The DTR sensor is located on the outside of the transmission (Figure 1) at the outer manual lever. ACTION: Refer to the following text to properly diagnose a concern with the DTR sensor. The new DTR sensor completes the start circuit in "Park" and "Neutral," the backup lamp circuit in "Reverse" and the neutral sense circuit (4X4 only) in "Neutral." The DTR sensor also opens/closes a set of four (4) switches that are monitored by the Powertrain Control Module (PCM) to determine the position of the transmission manual lever. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > New Digital Transmission Range Sensor - Service Tip > Page 3846 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > New Digital Transmission Range Sensor - Service Tip > Page 3847 To properly diagnose the DTR sensor, use the NGS, Rotunda Transmission Tester with TR/MLP Cable "E" (Figure 2) and the new DTR Sensor Overlay (Figure 4), while following the procedures outlined in the appropriate model 1997 Service Manual, Section 07-01 or appropriate model 1997 Workshop Manual, Section 307-01. The new DTR Sensor Overlay (007-00131) and updated Tester Manual was sent to all dealers in August 1996. The TR/MLP Cable "E" (007-00111) was sent to all dealers in June 1995 (refer to TSB 95-19-7). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > New Digital Transmission Range Sensor - Service Tip > Page 3848 When using Cable "E" (Figure 3) to diagnose the DTR sensor, the slide switch must be in the "Digital" position and the "Black" 12-pin connector installed on the sensor. Having the slide switch in the incorrect position or using the incorrect 12-pin connector will result in misdiagnosis and possible replacement of a good component. For diagnosis of the DTR sensor, always refer to the appropriate model 1997 Service Manual, Section 07.01 or appropriate model 1997 Workshop Manual, Section 3O7-01 for proper procedure and required equipment. OTHER APPLICABLE ARTICLES: 95-19-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 503000, 503300, 504000, 601300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3849 Transmission Position Switch/Sensor: Specifications TORQUE SPECIFICATIONS DTR Sensor Bolts ................................................................................................................................ ..................................... 7-10 Nm (62-89 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3850 Transmission Position Switch/Sensor: Locations Transmission View The Digital Transmission Range Sensor is located at left side of the automatic transmission. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3851 Digital Transmission Range Sensor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3852 Transmission Position Switch/Sensor: Adjustments NOTE: Use Digital Transmission Range (DTR) Sensor Alignment Tool to align both TR and DTR sensors. 1. Raise and support vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Disconnect the manual lever shift control cable. 3. Disconnect the TR or DTR electrical connector. 4. Remove the manual control lever. (1) Remove the nut. (2) Remove the lever. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. 5. Loosen the TR or DTR bolts. 6. Use DTR sensor alignment tool, to align the DTR or TR sensor slots. NOTE: Manual shift lever must be in the neutral position. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3853 7. Tighten the DTR or TR sensor bolts. 8. Install the manual control lever. (1) Position the manual control lever. (2) Install a new manual lever shaft outer nut. 9. With the manual lever in overdrive connect the shift lever control cable. 10. Install the DTR sensor electrical connector. 11. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications TORQUE SPECIFICATIONS Vehicle Speed Sensor (VSS) Bolt ........................................................................................................................................ 11-13 Nm (98-115 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 3857 Vehicle Speed Sensor: Locations Transmission View The Vehicle Speed Sensor is located at left rear of transmission. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3860 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3861 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3862 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3863 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3864 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3865 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3866 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 3867 Vehicle Speed Sensor: Description and Operation Purpose The Vehicle Speed (VSS) Sensor: - Is gear driven by the transmission. - Sends a signal to the PCM indicating transmission speed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 3868 Vehicle Speed Sensor: Service and Repair REMOVAL 1. Disconnect the battery. 2. Raise and support the vehicle. WARNING: The electrical power to the air suspension system must be shut OFF prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning OFF the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during 1 these operations. 3. Remove the Vehicle Speed Sensor (VSS). (1) Disconnect the electrical connector. (2) Remove the bolt. (3) Remove the VSS. 4. Remove the Vehicle Speed Sensor (VSS) drive gear. INSTALLATION 1. Install the Vehicle Speed Sensor (VSS) drive gear. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 3869 2. Install the VSS. (1) Install the VSS. (2) Install the bolt. (3) Connect the electrical connector. 3. Remove supports and lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning ON the air suspension switch. 4. Reconnect the battery ground cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Leak Detection Sensor, Evaporative System > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Leak Detection Sensor, Evaporative System > Component Information > Diagrams > Page 3874 Leak Detection Sensor: Description and Operation Fuel Tank Pressure (FTP) Sensor FUEL TANK PRESSURE SENSOR The Fuel Tank Pressure (FTP) sensor (A) is used to monitor the fuel tank pressure or vacuum during the OBD II purge monitor test of the Evaporative Emission System for Running Loss vehicles (passenger cars with fuel vapor control valves and trucks with fuel vapor valves). This monitor also performs a fuel system integrity check to determine if there is an evaporative emission system leak. Variations in pressure will be converted into an analog voltage input signal to the PCM. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision Pressure Feedback Exhaust Sensor: Technical Service Bulletins EGR DPFE Sensor - Voltage Range Revision Article No. 97-22-1 10/27/97 DELTA PRESSURE FEEDBACK EGR (DPFE) - DIAGNOSTIC TIPS FORD: 1994-97 MUSTANG, THUNDERBIRD 1995-97 CONTOUR, CROWN VICTORIA 1996-97 ESCORT, TAURUS LINCOLN-MERCURY: 1990-97 TOWN CAR 1994-97 COUGAR 1995-97 CONTINENTAL, GRAND MARQUIS, MYSTIQUE 1996-97 SABLE, TRACER LIGHT TRUCK: 1994-97 EXPLORER 1995-97 ECONOLINE, F-150-350 SERIES, WINDSTAR 1996-97 AEROSTAR 1997 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: The current DPFE sensor diagnostic reference values as published in the Powertrain Control/Emissions Diagnosis (PC/ED) Service Manual, and also accessed by either the Service Bay Diagnostic System (SBDS) or Service Bay Technical System (SBTS), can lead to the replacement of good DPFE sensors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision > Page 3879 ACTION: Use the following revised DPFE sensor voltage ranges for all (black plastic or aluminum) DPFE system applications when checking the PID (Parameter Identifier Display) value "DPFEGR" or when measuring the DPFE sensor input directly at the breakout box. Refer to Figure 1. NOTE: THESE LISTED VOLTAGE RANGES SHOULD BE USED FOR ALL (BLACK PLASTIC OR ALUMINUM) DPFE SYSTEM APPLICATIONS WHENEVER CHECKING THE PID VALUE "DPFEGR" OR WHEN MEASURING THE DPFE SENSOR INPUT DIRECTLY AT THE BREAKOUT BOX. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3880 Pressure Feedback Exhaust Sensor: Locations Engine View The Differential Pressure Feedback EGR (DPFE) Sensor is located at the right side of engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3890 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3891 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3897 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3898 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement Air Flow Meter/Sensor: All Technical Service Bulletins Mass Air Flow Sensor - Assembly Replacement Article No. 96-22-5 10/21/96 MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP FORD: 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR, EXPLORER, RANGER 1993-97 VILLAGER 1994-96 BRONCO 1994-97 ECONOLINE 1995-97 F-150, WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: The Mass Air Flow (MAF) sensor is not designed to be removed from its body (die-cast or plastic) for servicing. The sensing elements located inside the by-pass tube can be damaged by poking/probing/touching. ACTION: Service the MAF sensor as an assembly (refer to Figure 1). WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement > Page 3903 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement Air Flow Meter/Sensor: All Technical Service Bulletins Mass Air Flow Sensor - Assembly Replacement Article No. 96-22-5 10/21/96 MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP FORD: 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR, EXPLORER, RANGER 1993-97 VILLAGER 1994-96 BRONCO 1994-97 ECONOLINE 1995-97 F-150, WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: The Mass Air Flow (MAF) sensor is not designed to be removed from its body (die-cast or plastic) for servicing. The sensing elements located inside the by-pass tube can be damaged by poking/probing/touching. ACTION: Service the MAF sensor as an assembly (refer to Figure 1). WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement > Page 3909 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3910 Air Flow Meter/Sensor: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3911 RH Component The Mass Air Flow Sensor is located in air cleaner assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3912 Air Flow Meter/Sensor: Description and Operation PURPOSE The Mass Air Flow (MAF) sensor: - Sends the PCM a signal indicating mass airflow rate of air entering the engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal Air Flow Meter/Sensor: Service and Repair Removal REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Open the engine air cleaner. - Disconnect the Mass Air Flow (MAF) sensor connector from the wiring harness. - Release the air cleaner clamp. Separate the inlet side of the air cleaner from the outlet side of the air cleaner. 3. Cut the tape on the wire loom of the extension harness. CAUTION: Do not cut the MAF sensor wires when cutting the tape on the wire loom. - Peel back the wire loom from the extension harness near the grommet in the air cleaner. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal > Page 3915 4. Remove the grommet from the outlet side of the air cleaner and slide the grommet down the extension harness. 5. Remove the MAF sensor plate and MAF sensor from the outlet side of the engine air cleaner. 6. Disconnect the MAF sensor electrical connector. 7. Remove the nuts and separate the MAF plate from the MAF sensor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal > Page 3916 Air Flow Meter/Sensor: Service and Repair Installation INSTALLATION CAUTION: - Do not tamper with the MAF sensing elements located in the airflow bypass; tampering may result in unit failure. - The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. NOTE: - Use the alignment notch to properly align the inlet side and the outlet side of the engine air cleaner. - The MAF sensor module and body are calibrated and replaced as a unit. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations Inertia Fuel Shutoff Switch: Locations The inertia fuel shutoff switch is located under the RH cowl side trim (kick) panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3920 Inertia Fuel Shutoff Switch: Service Precautions WARNING: Do not reset the Inertia Fuel Shutoff switch (IFS) switch until the complete fuel system has been inspected for leaks. Damage to the vehicle or personal injury may occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3921 Inertia Fuel Shutoff Switch: Description and Operation Typical Inertia Fuel Shut-Off Switch Description The inertia fuel shutoff switch: - is used in conjunction with an electric fuel pump. - shuts off the fuel pump in the event of a collision. - consists of a steel ball held in place by a magnet. Operation When a sharp impact occurs: - the ball breaks loose from the magnet, rolls up a ramp and strikes a target plate which opens the electrical contacts of the inertia fuel shutoff switch and shuts off the fuel pump. - Once the inertia fuel shutoff switch is open, the inertia fuel shutoff switch must be manually reset before restarting the vehicle. If a collision occurs: - the electrical contacts in the inertia fuel shutoff switch open. - the fuel pump automatically shuts off, even if the engine does not stop running. - the engine will stop a few seconds after the fuel pump stops. - it is impossible to restart engine until the inertia fuel shutoff switch, located on the LH side lower back panel in the luggage compartment, is manually reset. NOTE:In the reset position, the button can be pressed an additional 1.59 mm (0.0625 inch) against a spring. This is a normal condition. WARNING: Do not reset the inertia fuel shutoff switch until the complete fuel system has been inspected for leaks or damage to vehicle or personal injury may occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3922 Inertia Fuel Shutoff Switch: Testing and Inspection To avoid potential misdiagnosis and the unnecessary replacement of components, it is recommended that diagnosis and testing begin with Diagnostic Routines (Diagnosis by Symptom) at the Powertrain Management level. The Diagnostic Routines will lead the technician through the logical and methodical testing of a "specific" subsystem and it's related wiring and components. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3923 Inertia Fuel Shutoff Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Remove the RH cowl side trim panel. 3. Disconnect the inertia fuel shutoff switch electrical connector. 4. Remove the inertia fuel shutoff switch. 1 Remove inertia switch bolts. 2 Remove the inertia fuel shutoff switch. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3924 To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Specifications Oil Pressure Switch (For Fuel Pump): Specifications Oil Pressure Switch 12-16 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Specifications > Page 3928 Oil Pressure Switch (For Fuel Pump): Testing and Inspection To avoid potential misdiagnosis and the unnecessary replacement of components, it is recommended that diagnosis and testing begin with Diagnostic Routines (Diagnosis by Symptom) at the Powertrain Management level. The Diagnostic Routines will lead the technician through the logical and methodical testing of a "specific" subsystem and it's related wiring and components. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Specifications > Page 3929 Oil Pressure Switch (For Fuel Pump): Service and Repair REMOVAL 1. Disconnect the oil pressure switch electrical connector. 2. Remove the oil pressure switch from the oil filter adapter. INSTALLATION 1. To install, reverse the removal procedure. 2. Check the oil level and fill to specification with Ford Premium SAE 1OW-30 Motor Oil XO-1OW-30-BSP, DSP, QSP or equivalent meeting Ford specification ESE-M2C153-E. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Retaining Screws 2.8-3.4 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3933 Throttle Position Sensor: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3934 The Throttle Position Sensor is attached to the throttle body. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3935 Throttle Position Sensor: Description and Operation PURPOSE The Throttle Position Sensor (TP): - Sends the PCM a signal indicating the throttle plate angle. - Is the main input to the PCM from the driver. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3936 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Remove the accelerator control splash shield. 1 Remove three accelerator splash shield bolts. 2 Remove the accelerator control splash shield from the vehicle. 3. Remove the Throttle Position (TP) sensor. 1 Disconnect the electrical connector. 2 Remove the two bolts. 3 Remove the TP sensor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3937 To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt 8-12 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3942 Camshaft Position Sensor: Locations Engine View The Camshaft Position Sensor is located in front of the engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3943 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3944 Camshaft Position Sensor: Description and Operation The Camshaft Position (CMP) sensor: - Sends the PCM a signal indicating camshaft position, which is used for fuel synchronization. NOTE: The Camshaft Position (CMP) sensor is also referred to as Cylinder Identification Sensor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3945 Camshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the CMP sensor. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Retainer Torque 8-12 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3949 Crankshaft Position Sensor: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3950 The Crankshaft Position Sensor is located at the lower front of engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3951 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) sensor: - Sends the PCM a signal indicating crankshaft position. - Is essential for calculating spark timing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3952 Crankshaft Position Sensor: Service and Repair REMOVAL WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 3. Release the tension on the accessory drive belt. 1. Remove the A/C compressor. 1 Remove the A/C compressor bolts. 2 Remove the A/C compressor and position aside. NOTE: Do not remove lines from the A/C compressor. 5. Remove the (A) CKP sensor bolt and the (B) CKP sensor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3953 To install, reverse the removal procedure NOTE:If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 3959 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 3960 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 3961 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 3962 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 3963 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Ignition Switch Lock Cylinder: Service and Repair Functional REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key and turn to the RUN position. (2) Press the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. INSTALLATION 1. To install, reverse the removal procedure. - Verify ignition switch lock cylinder operation. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 3966 Ignition Switch Lock Cylinder: Service and Repair Non-Functional REMOVAL 1. Disconnect the battery ground cable. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. 4. Remove the ignition switch lock cylinder. - Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. - Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the bearing and the gear. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 3967 - Thoroughly clean all drill shavings from the steering column and inspect for damage. INSTALLATION 1. To install, reverse the removal procedure, using a new ignition switch lock cylinder. - Verify ignition switch lock cylinder operation. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor 20-27 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 3971 Knock Sensor: Description and Operation The knock sensor is located in the lifter valley and: - Sends a signal to the PCM indicating engine detonation. - If detonation is occurring, the PCM then changes engine timing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 3972 Knock Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the Knock Sensor (KS) . 1 Disconnect the electrical connector. 2 Remove the KS. INSTALLATION 1. Install the Knock Sensor (KS) 1 Install the KS. 2 Connect the electrical connector. 2. Install the intake manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications Fuel Pressure Test Port: Specifications Pressure Relief Valve 7.75 Nm Pressure Relief Valve Cap 0.6 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 3978 Fuel Pressure Test Port: Locations Typical Location The fuel pressure test point/port is a Schrader fitting, located in the fuel rail. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 3979 Fuel Pressure Test Port: Service Precautions WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited, resulting in possible injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. - Before repairing or disconnecting any of the fuel lines or fuel system components, the fuel system fuel pressure release procedure must be performed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 3980 Fuel Pressure Test Port: Description and Operation Typical Location Purpose There is a pressure test point with a Schrader fitting in the fuel rail, which is used for fuel pressure release and to measure the injector supply pressure for service and diagnostic work. NOTE:Before servicing or testing the fuel system, read CAUTION, WARNING, and HANDLING information. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 3981 Fuel Pressure Test Port: Service and Repair REMOVAL 1. Perform Fuel Pressure Release Procedure 2. Remove the fuel pressure relief valve. INSTALLATION To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > System Diagnosis Air/Fuel Mixture: Testing and Inspection To avoid potential misdiagnosis and the unnecessary replacement of components, it is recommended that diagnosis and testing begin with Diagnostic Routines (Diagnosis by Symptom) at the Powertrain Management level. The Diagnostic Routines will lead the technician through the logical and methodical testing of a "specific" subsystem and it's related wiring and components. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > System Diagnosis > Page 3985 Air/Fuel Mixture: Adjustments Air Fuel Ratio is NOT adjustable. If a problem exists, or is suspected, go to the Diagnostic Charts: See Powertrain Management Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Idle Speed (Non-Adjustable) Idle Speed (Non-Adjustable) Base Idle Speed (Standard Trans/Hot) 750 +/- 25 rpm Base Idle Speed (Automatic Trans/Hot) 824 +/- 25 rpm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 3989 Idle Speed: Adjustments Engine Idle RPM is controlled by the PCM and is NOT adjustable. If a problem exists, or is suspected, see: Powertrain Management / Symptom Charts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Tube Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Outlet Tube REMOVAL 1. Remove the accelerator control splash shield. 1 Remove the accelerator control splash shield bolts. 2 Remove the accelerator control splash shield. 2. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 3. Disconnect the (A) positive crankcase ventilation hose and the (B) idle air control valve inlet tube. 4. Loosen the two air cleaner outlet tube hose clamp screws and remove the air cleaner outlet tube. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Tube > Page 3995 To install, reverse the removal procedure. CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Tube > Page 3996 Air Cleaner Fresh Air Duct/Hose: Service and Repair Removal and Installation REMOVAL 1. Open the (A) air cleaner clamp and set the (B) outlet engine air cleaner aside. 2. Lift the (B) open end of the (A) inlet engine air cleaner until free of the (C) engine air cleaner support insulators. CAUTION: The inlet engine air cleaner should be removed as an assembly. Do not separate the air cleaner from the fender inlet tube during removal or installation. 3. Pull the inlet engine air cleaner away from the inner fender. INSTALLATION CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. NOTE: The inlet engine air cleaner has an alignment tab which fits into a slot on the outlet engine air cleaner. This ensures a good seal and keeps unmetered air from entering the engine. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL 1. Open the (A) air cleaner clamp and set the (B) outlet engine air cleaner aside. 2. Remove the (A) air cleaner element from the (B) open end of the inlet engine air cleaner. INSTALLATION 1. Install the air cleaner element. NOTE: The inlet engine air cleaner has an alignment tab which fits into a slot on the outlet engine air cleaner. This ensures a good seal and keeps unmetered air from entering the engine. CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. 2. Position the engine air cleaner aligning the alignment tab. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 4000 3. Close the air cleaner clamp. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Locations Fuel Pressure Release: Locations Fuel Pressure Port (Typical) A fuel system service port is provided on the fuel rail. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Locations > Page 4005 Fuel Pressure Release: Service Precautions WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited, resulting in possible injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. - Before repairing or disconnecting any of the fuel lines or fuel system components, the fuel system fuel pressure release procedure must be performed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Locations > Page 4006 Fuel Pressure Release: Service and Repair Fuel Pressure Port (Typical) 1. Remove the schrader valve cap and attach EFI/CFI Fuel Pressure Gauge. 2. Open the manual valve on EFI/CFI Fuel Pressure Gauge and Perform Fuel Pressure Release. NOTE: Open manual value slowly to relieve system pressure. - This will drain some fuel out of the system. - Place fuel in suitable a container. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications The RH (Passenger's) side ................................................................................................................. ................................................ Cylinders 1, 2, 3, and 4 The LH (Driver's side) .......................................................................................................................... ............................................. Cylinders 5, 6, 7 and 8 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 4010 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 4011 Firing Order 1-3-7-2-6-5-4-8 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Firing Order Firing Order: 1-3-7-2-6-5-4-8 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Locations Timing Marks and Indicators: Locations The timing marks are located on the crankshaft pulley/damper. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Secondary Suppression Resistor, Ignition > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 962523 > Dec > 96 > Spark Plug Wires - MIL ON/DTCs P0300 Through P0308 Set Spark Plug: Customer Interest Spark Plug Wires - MIL ON/DTCs P0300 Through P0308 Set Article No. 96-25-23 12/02/96 ^ RUNS ROUGH - MALFUNCTION INDICATOR LAMP (MIL) ON-DIAGNOSTIC TROUBLE CODES (DTCS) P0300 THROUGH P0308 STORED IN MEMORY - VEHICLES BUILT THROUGH 10/14/96 WITH 4.6L ENGINE ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ON - RUNS ROUGH - DIAGNOSTIC TROUBLE CODES (DTCS) P0300 THROUGH P0308 STORED IN MEMORY - VEHICLES BUILT THROUGH 10/14/96 WITH 4.6L ENGINE LIGHT TRUCK: 1997 ECONOLINE, EXPEDITION, F-150 ISSUE: The Malfunction Indicator Lamp (MIL) may illuminate and Diagnostic Trouble Codes (DTCs) P0300 through P0308 may be stored in memory and/or the engine may run rough. This may be caused by water intrusion into the spark plug well causing the spark to travel directly to ground instead of through the spark plug, resulting in a misfire. ACTION: Inspect the spark plugs for signs of moisture and replace the spark plugs and spark plug wires. Apply dielectric compound on all of the spark plug wire boots. The new spark plug wires and the dielectric compound should reduce the possibility of misfire if water intrusion into the spark plug well occurs. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect and remove any water that may be sitting in the spark plug wells by blowing out the water using compressed air. 2. Inspect the spark plugs for signs of "tracking." If "tracking" is present, there may be a fine, broken "pencil" line on the blue rings only and/or a thick smudgy series of continuous lines depending on how long the vehicle was operated while misfiring. These lines may feel like a crack if the fingernail is rubbed across the lines. Refer to Figure 1. 3. If "tracking" is found, replace all eight (8) of the spark plugs and torque the new Spark Plugs (AWSF-32-PP) to 16-20 N.m (12-15 lb-ft). 4. Replace all eight (8) of the Spark Plug Wires with new wires (F6PZ-12259-HC). Be sure to apply Silicone Caliper Grease and Dielectric Compound (D7AZ-19A331-A) on the inside of all spark plug wire boots. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 962523 > Dec > 96 > Spark Plug Wires - MIL ON/DTCs P0300 Through P0308 Set > Page 4031 5. Position the spark plug wire boots 90 degrees to the crankshaft centerline with the spark plug wires facing outboard. The lip of the spark plug wire boot must be flush to the manifold. Refer to Figure 2. PART NUMBER PART NAME F6PZ-12259-HC Spark Plug Wires AWSF-32-PP Spark Plug D7AZ-19A331-A Silicone caliper Grease And Dielectric Compound OTHER APPLICABLE ARTICLES: 96-20-5 960923 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 962523 > Dec > 96 > Spark Plug Wires - MIL ON/DTCs P0300 Through P0308 Set > Page 4032 OPERATION DESCRIPTION TIME 962523A Replace Spark Plugs And 1.1 Hr. Wires DEALER CODING CONDITION BASIC PART NO. CODE 12286 48 OASIS CODES: 206000, 608400, 608500, 608600, 609000, 609400, 609500, 609600, 609800, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 962523 > Dec > 96 > Spark Plug Wires - MIL ON/DTCs P0300 Through P0308 Set Spark Plug: All Technical Service Bulletins Spark Plug Wires - MIL ON/DTCs P0300 Through P0308 Set Article No. 96-25-23 12/02/96 ^ RUNS ROUGH - MALFUNCTION INDICATOR LAMP (MIL) ON-DIAGNOSTIC TROUBLE CODES (DTCS) P0300 THROUGH P0308 STORED IN MEMORY - VEHICLES BUILT THROUGH 10/14/96 WITH 4.6L ENGINE ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ON - RUNS ROUGH - DIAGNOSTIC TROUBLE CODES (DTCS) P0300 THROUGH P0308 STORED IN MEMORY - VEHICLES BUILT THROUGH 10/14/96 WITH 4.6L ENGINE LIGHT TRUCK: 1997 ECONOLINE, EXPEDITION, F-150 ISSUE: The Malfunction Indicator Lamp (MIL) may illuminate and Diagnostic Trouble Codes (DTCs) P0300 through P0308 may be stored in memory and/or the engine may run rough. This may be caused by water intrusion into the spark plug well causing the spark to travel directly to ground instead of through the spark plug, resulting in a misfire. ACTION: Inspect the spark plugs for signs of moisture and replace the spark plugs and spark plug wires. Apply dielectric compound on all of the spark plug wire boots. The new spark plug wires and the dielectric compound should reduce the possibility of misfire if water intrusion into the spark plug well occurs. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect and remove any water that may be sitting in the spark plug wells by blowing out the water using compressed air. 2. Inspect the spark plugs for signs of "tracking." If "tracking" is present, there may be a fine, broken "pencil" line on the blue rings only and/or a thick smudgy series of continuous lines depending on how long the vehicle was operated while misfiring. These lines may feel like a crack if the fingernail is rubbed across the lines. Refer to Figure 1. 3. If "tracking" is found, replace all eight (8) of the spark plugs and torque the new Spark Plugs (AWSF-32-PP) to 16-20 N.m (12-15 lb-ft). 4. Replace all eight (8) of the Spark Plug Wires with new wires (F6PZ-12259-HC). Be sure to apply Silicone Caliper Grease and Dielectric Compound (D7AZ-19A331-A) on the inside of all spark plug wire boots. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 962523 > Dec > 96 > Spark Plug Wires - MIL ON/DTCs P0300 Through P0308 Set > Page 4038 5. Position the spark plug wire boots 90 degrees to the crankshaft centerline with the spark plug wires facing outboard. The lip of the spark plug wire boot must be flush to the manifold. Refer to Figure 2. PART NUMBER PART NAME F6PZ-12259-HC Spark Plug Wires AWSF-32-PP Spark Plug D7AZ-19A331-A Silicone caliper Grease And Dielectric Compound OTHER APPLICABLE ARTICLES: 96-20-5 960923 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 962523 > Dec > 96 > Spark Plug Wires - MIL ON/DTCs P0300 Through P0308 Set > Page 4039 OPERATION DESCRIPTION TIME 962523A Replace Spark Plugs And 1.1 Hr. Wires DEALER CODING CONDITION BASIC PART NO. CODE 12286 48 OASIS CODES: 206000, 608400, 608500, 608600, 609000, 609400, 609500, 609600, 609800, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Electrode Gap 1.32-1.42 mm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 4042 Spark Plug: Specifications Spark Plug 9-20 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 4043 Spark Plug: Locations The Spark Plugs are located along the inboard sides of the cylinder heads, and outboard of the intake manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 4044 Spark Plug: Application and ID RH Original Spark Plug ....................................................................................................................... ........................................................ AWSF32PG (a) LH Original Spark Plug ..................................... ............................................................................................................................................. AWSF32P (a) Replacement Spark Plug (Either Side) ......................................................................................................................................................... AWSF32PP (a) (a) If a spark plug is removed for examination, it must be reinstalled in the same cylinder. If a spark plug needs to be replaced, use only spark plugs with the base part number suffix "PP" as shown on the engine decal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 4045 Spark Plug: Description and Operation Spark Plug Construction PURPOSE Ignites the combustion mixture. LOCATION Threaded into the cylinder head, at the combustion chamber. OPERATION The spark plug provides a path for the high current of the secondary circuit to flow to ground. The only paths for this current are through the ground electrode and center electrode across the spark gap. The spark produced when the current jumps the gap and ignites the air/fuel mixture in the cylinder. Spark Plug Heat Range CONSTRUCTION The temperature of the spark plug is determined by the length of the insulator and the size of the heatsink area. The longer the insulator is, the smaller the heatsink area will be and this will cause the spark plug to be hotter. - Change high voltage pulses to spark at gap which ignites fuel and air mixture. - Have a platinum enhanced active electrode for long life. FEATURES The active electrode is different for LH and RH spark plugs: - On the RH side (cylinders 1, 2, 3, and 4) are type AWSF-32PG. - On the LH side (cylinders 5, 6, 7 and 8) are type AWSF-32P. NOTE: The replacement spark plugs are AWSF-32PP; both electrodes are platinum enhanced so it can replace either a RH or LH spark plug. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 4046 Spark Plug: Testing and Inspection CLEANING AND INSPECTION Spark Plugs Inspect the electrodes and outer surface. Refer to Spark Plug Inspection Chart. Replace spark plugs if they are worn or damaged. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 4047 Spark Plug: Adjustments Gapping Spark Plug Check and set the spark plug electrode gap to: 1.32-1.41 mm (0.052-0.056 inch) using an appropriate gapping tool. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 4048 Spark Plug: Service and Repair REMOVAL NOTE: - If an original spark plug is reused, make sure it is placed in the same cylinder it was taken from. Replacement spark plugs can be used in any cylinder. - Use compressed air to remove any debris from the spark plug well before removing the spark plugs. 1. With a twisting, pulling motion disconnect the spark plug wire from the spark plug. 2. Squeeze the (A) locking tabs and disconnect the (B) spark plug wire from the (C) ignition coil. 3. Remove the RH spark plugs. 4. Remove the LH spark plugs. 5. Inspect the spark plugs for: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 4049 - Deposits bridging spark plug gap (A). - Wet black deposits (oil fouling) (B). - Dry black deposits (carbon fouling) (C). - Overheating (D). - Deposits fused on spark plug (E). Pre-ignition damage (F). - Normal spark plug (G). INSTALLATION NOTE: If an original spark plug is reused, make sure it is placed in the same cylinder it was taken from. Replacement spark plugs can be used in any cylinder. 1. Apply Silicone Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A to inside of spark plug wire boots. 2. Adjust the spark plug gap as required. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 4050 3. Install the LH spark plugs. 4. Install the RH spark plugs. 5. Connect the spark plug wires. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart above. If one or more cylinders reads low, squirt approximately one tablespoon of clean engine oil meeting Ford specification ESE-M2C153-E on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Gauge Check Compression Check: Testing and Inspection Gauge Check 1. Make sure the oil in the crankcase is of the correct viscosity and at the proper level and that the battery is properly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as Compression Tester in No.1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, use the auxiliary starter switch to crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Gauge Check > Page 4056 Compression Check: Testing and Inspection Interpreting Compression Readings 1. If compression improves considerably, the piston rings are faulty. 2. If compression does not improve, the valves are sticking or seating improperly. 3. If two adjacent cylinders indicate low compression pressures and squirting oil on the piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil and/or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75 percent of the highest reading. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Gauge Check > Page 4057 Compression Check: Testing and Inspection Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart above. If one or more cylinders reads low, squirt approximately one tablespoon of clean engine oil meeting Ford specification ESE-M2C153-E on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Gauge Check > Page 4058 Compression Check: Testing and Inspection Cylinder Leakage Test When a cylinder produces a low reading, the use of Engine Cylinder Leak Detection/Air Pressurization Kit will be helpful in pinpointing the exact cause. The leakage detector is inserted in the spark plug hole, the piston is brought up to dead center on the compression stroke, and compressed air is admitted. Once the combustion chamber is pressurized, a special gauge included in the kit will read the percentage of leakage. Leakage exceeding 20 percent is excessive. While the air pressure is retained in the cylinder, listen for the hiss of escaping air. A leak at the intake valve will be heard in the throttle body. A leak at the exhaust valve can be heard at the tail pipe. Leakage past the piston rings will be audible at the positive crankcase ventilation (PCV) connection. If air is passing through a blown head gasket to an adjacent cylinder, the noise will be evident at the spark plug hole of the cylinder into which the air is leaking. Cracks in the cylinder block or gasket leakage into the cooling system may be detected by a stream of bubbles in the radiator. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Hydraulic lash adjusters provide automatic lash compensation. No adjustment is necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 4062 Valve Clearance: Adjustments Hydraulic lash adjusters provide automatic lash compensation. No adjustment is necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4072 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4073 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4079 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4080 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement Air Flow Meter/Sensor: All Technical Service Bulletins Mass Air Flow Sensor - Assembly Replacement Article No. 96-22-5 10/21/96 MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP FORD: 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR, EXPLORER, RANGER 1993-97 VILLAGER 1994-96 BRONCO 1994-97 ECONOLINE 1995-97 F-150, WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: The Mass Air Flow (MAF) sensor is not designed to be removed from its body (die-cast or plastic) for servicing. The sensing elements located inside the by-pass tube can be damaged by poking/probing/touching. ACTION: Service the MAF sensor as an assembly (refer to Figure 1). WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement > Page 4085 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement Air Flow Meter/Sensor: All Technical Service Bulletins Mass Air Flow Sensor - Assembly Replacement Article No. 96-22-5 10/21/96 MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP FORD: 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR, EXPLORER, RANGER 1993-97 VILLAGER 1994-96 BRONCO 1994-97 ECONOLINE 1995-97 F-150, WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: The Mass Air Flow (MAF) sensor is not designed to be removed from its body (die-cast or plastic) for servicing. The sensing elements located inside the by-pass tube can be damaged by poking/probing/touching. ACTION: Service the MAF sensor as an assembly (refer to Figure 1). WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement > Page 4091 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 4092 Air Flow Meter/Sensor: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 4093 RH Component The Mass Air Flow Sensor is located in air cleaner assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 4094 Air Flow Meter/Sensor: Description and Operation PURPOSE The Mass Air Flow (MAF) sensor: - Sends the PCM a signal indicating mass airflow rate of air entering the engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal Air Flow Meter/Sensor: Service and Repair Removal REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Open the engine air cleaner. - Disconnect the Mass Air Flow (MAF) sensor connector from the wiring harness. - Release the air cleaner clamp. Separate the inlet side of the air cleaner from the outlet side of the air cleaner. 3. Cut the tape on the wire loom of the extension harness. CAUTION: Do not cut the MAF sensor wires when cutting the tape on the wire loom. - Peel back the wire loom from the extension harness near the grommet in the air cleaner. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal > Page 4097 4. Remove the grommet from the outlet side of the air cleaner and slide the grommet down the extension harness. 5. Remove the MAF sensor plate and MAF sensor from the outlet side of the engine air cleaner. 6. Disconnect the MAF sensor electrical connector. 7. Remove the nuts and separate the MAF plate from the MAF sensor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal > Page 4098 Air Flow Meter/Sensor: Service and Repair Installation INSTALLATION CAUTION: - Do not tamper with the MAF sensing elements located in the airflow bypass; tampering may result in unit failure. - The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. NOTE: - Use the alignment notch to properly align the inlet side and the outlet side of the engine air cleaner. - The MAF sensor module and body are calibrated and replaced as a unit. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 4102 Engine View The Intake Air Temperature Sensor is located on the air intake tube. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 4103 Intake Air Temperature Sensor: Description and Operation PURPOSE The Intake Air Temperature (IAT) sensor: - Sends the PCM a signal indicating the temperature of the air entering the engine. - It's resistance decreases as temperature increases. - The PCM uses the air temperature information as a correction factor in the calculation of fuel, spark and MAF. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 4104 Intake Air Temperature Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 3. Remove the IAT sensor. INSTALLATION To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set Auxiliary Air Valve (Idle Speed): Customer Interest Engine - Fast Idle Speed/MIL ON/DTC P1506 Set Article No. 98-21-21 10/26/98 ^ IDLE - FAST IDLE SPEED AND/OR DIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY - VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE ^ MALFUNCTION INDICATOR LAMP (MIL) - MIL ILLUMINATED AND/OR FAST IDLE SPEED WITH 31GDIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY - VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED AND/OR FAST IDLE SPEED WITH DIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY-VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE LIGHT TRUCK: 1997-98 ECONOLINE, EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 4113 This TSB article is being republished in its entirety to add service parts, include a Part Application Chart, and to revise Figure 1. ISSUE The Malfunction Indicator Lamp (MIL) may illuminate and Diagnostic Trouble Code (DTC) P1506 may be stored in continuous memory and/or the engine idle speed may be higher than expected. This may be caused by black plastic flash from idle air bypass hose becoming lodged in the Idle Air Control (IAC) bypass valve. ACTION Refer to the Diagnostic Flow Chart (Figure 1) for diagnostic and servicing procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 4114 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-13-17 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 982121A Perform TSB Diagnostics 0.8 Hr. (Includes Replace Idle Air Control Resonator And Inspect Or Replace Idle Air Control Valve) Vehicles Built Before 4/15/98 982121B Perform TSB Diagnostics 0.5 Hr. (Includes Replace Idle Air Control Valve) - Vehicles Built After 4/15/98 DEALER CODING CONDITION BASIC PART NO. CODE 9H308 42 OASIS CODES: 206000, 608000, 608400, 619400, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set Auxiliary Air Valve (Idle Speed): All Technical Service Bulletins Engine - Fast Idle Speed/MIL ON/DTC P1506 Set Article No. 98-21-21 10/26/98 ^ IDLE - FAST IDLE SPEED AND/OR DIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY - VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE ^ MALFUNCTION INDICATOR LAMP (MIL) - MIL ILLUMINATED AND/OR FAST IDLE SPEED WITH 31GDIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY - VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED AND/OR FAST IDLE SPEED WITH DIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY-VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE LIGHT TRUCK: 1997-98 ECONOLINE, EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 4120 This TSB article is being republished in its entirety to add service parts, include a Part Application Chart, and to revise Figure 1. ISSUE The Malfunction Indicator Lamp (MIL) may illuminate and Diagnostic Trouble Code (DTC) P1506 may be stored in continuous memory and/or the engine idle speed may be higher than expected. This may be caused by black plastic flash from idle air bypass hose becoming lodged in the Idle Air Control (IAC) bypass valve. ACTION Refer to the Diagnostic Flow Chart (Figure 1) for diagnostic and servicing procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 4121 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-13-17 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 982121A Perform TSB Diagnostics 0.8 Hr. (Includes Replace Idle Air Control Resonator And Inspect Or Replace Idle Air Control Valve) Vehicles Built Before 4/15/98 982121B Perform TSB Diagnostics 0.5 Hr. (Includes Replace Idle Air Control Valve) - Vehicles Built After 4/15/98 DEALER CODING CONDITION BASIC PART NO. CODE 9H308 42 OASIS CODES: 206000, 608000, 608400, 619400, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt 8-12 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 4125 Camshaft Position Sensor: Locations Engine View The Camshaft Position Sensor is located in front of the engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 4126 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 4127 Camshaft Position Sensor: Description and Operation The Camshaft Position (CMP) sensor: - Sends the PCM a signal indicating camshaft position, which is used for fuel synchronization. NOTE: The Camshaft Position (CMP) sensor is also referred to as Cylinder Identification Sensor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 4128 Camshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the CMP sensor. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Coolant Temperature Sensor Coolant Temperature Sensor/Switch (For Computer): Locations Coolant Temperature Sensor Engine View The Engine Coolant Temperature Sensor is located in front of the engine. NOTE: In some applications of the 4.6L engine, the Cylinder Head Temperature (CHT) sensor provides the signal used by the Powertrain Control Module (PCM) in place of the Coolant Temperature Sensor (CTS) for functions such as, but not limited to, activating the electric cooling fans. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Coolant Temperature Sensor > Page 4133 Engine Views Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4134 Coolant Temperature Sensor/Switch (For Computer): Description and Operation The Engine Coolant Temperature (ECT) sensor: - Sends the PCM a signal indicating engine temperature. - Resistance decreases as coolant temperature increases. NOTE: In some applications of the 4.6L engine, the Cylinder Head Temperature (CHT) sensor provides the signal used by the Powertrain Control Module (PCM) in place of the Coolant Temperature Sensor (CTS) for functions such as, but not limited to, activating the electric cooling fans. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4135 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Partially drain the cooling system. 3. Remove the Engine Coolant Temperature (ECT) sensor . 1 Disconnect the electrical connector. 2 Remove the ECT sensor. INSTALLATION 1. Install the ECT. 2. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Retainer Torque 8-12 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 4139 Crankshaft Position Sensor: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 4140 The Crankshaft Position Sensor is located at the lower front of engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 4141 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) sensor: - Sends the PCM a signal indicating crankshaft position. - Is essential for calculating spark timing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 4142 Crankshaft Position Sensor: Service and Repair REMOVAL WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 3. Release the tension on the accessory drive belt. 1. Remove the A/C compressor. 1 Remove the A/C compressor bolts. 2 Remove the A/C compressor and position aside. NOTE: Do not remove lines from the A/C compressor. 5. Remove the (A) CKP sensor bolt and the (B) CKP sensor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 4143 To install, reverse the removal procedure NOTE:If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Data Link Connector: Locations Instrument Panel View The Data Link Connector is located behind the center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions Data Link Connector: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4149 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4150 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4151 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4152 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4153 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4154 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4155 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4156 Data Link Connector Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Backpressure Transducer > Component Information > Specifications EGR Backpressure Transducer: Specifications Backpressure Transducer Nuts 8-12 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Backpressure Transducer > Component Information > Specifications > Page 4160 EGR Backpressure Transducer: Description and Operation The EGR backpressure transducer: - Monitors the EGR flow rate through the EGR valve to exhaust manifold tube. - Sends an EGR flow rate signal to the PCM. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Backpressure Transducer > Component Information > Specifications > Page 4161 EGR Backpressure Transducer: Service and Repair REMOVAL 1. Remove the EGR backpressure transducer. 1 Remove the two EGR backpressure transducer tubes. 2 Disconnect the EGR backpressure transducer electrical connector. 3 Remove the two nuts. 4 Remove the EGR backpressure transducer. INSTALLATION To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures Engine Control Module: Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 4166 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 4167 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 4168 Engine Control Module: Technical Service Bulletins PCM - Reprogramming Out of Vehicle Article No. 99-4-3 03/08/99 REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V VEHICLES ONLY FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97 PROBE 1996-99 CONTOUR, ESCORT, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to update the affected vehicles and to include an Application Chart for the affected vehicles. ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain reasonably priced, timely PCM programming services at dealerships. Ford has released an out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are reprogrammable to update calibration levels or to reprogram a common hardware type to a new calibration in order to fill a service need without ordering a new PCM. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 4169 ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to have modules updated to new calibrations through the Parts Department instead of ordering new parts. Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the module. An aftermarket service center may bring a module to a dealership for a calibration update or may request an updated calibration be installed to a new service part. The EPA regulations require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a calibration on a PCM out of the vehicle. The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector. The proper calibration must be downloaded to the Data Transfer Card through Service Bay Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is connected, follow the calibration download instructions displayed on the NGS screen. The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling 1-800-ROTUNDA. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-26-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 206000, 290000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 4170 Engine Control Module: Technical Service Bulletins PCM - Reprogramming Tips Article No. 97-9-8 04/28/97 POWERTRAIN CONTROL MODULE - REPROGRAM POWERTRAIN CONTROL MODULE (PCM) - SERVICE PROCEDURES - SERVICE TIP FORD: 1994-97 CROWN VICTORIA, MUSTANG, THUNDERBIRD 1996-97 CONTOUR, ESCORT, PROBE, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR, GRAND MARQUIS 1995-97 CONTINENTAL, TOWN CAR 1996-97 MARK VIII, MYSTIQUE, SABLE, TRACER LIGHT TRUCK: 1994-97 ECONOLINE, F-150-350 SERIES 1995-97 RANGER 1995-98 WINDSTAR 1996 BRONCO 1996-97 AEROSTAR, EXPLORER 1997 EXPEDITION, MOUNTAINEER This TSB article is being republished in its entirety to include Windstar. ISSUE: Powertrain Control Modules (PCMs) no longer need to be replaced when servicing driveability concerns. The only time a PCM needs replacing is when it can no longer be reprogrammed and/or is damaged. In all other cases, the PCM must be reprogrammed and NOT REPLACED. ACTION: Use the following Service Procedure to properly reprogram a PCM. SERVICE PROCEDURE PCM REPROGRAMMING USING SBDS 1. At the Main menu, select Powertrain and enter the Vehicle Identification Number (VIN). Select "Continue." 2. From the Powertrain menu, select Electronic Engine category. 3. Scroll through the "Tool List" to PCM Reprogramming and select "Continue." 4. Any TSBs or Recalls for the entered vehicle will be displayed. There is up to a 6 week delay for TSB/Recall information updates on SBDS. New TSBs/Recalls may not appear or only the TSB number will be displayed even though the new calibration is on the current calibration CD-ROM. Also, if the vehicle calibration is being updated because of a Special Service Message, Broadcast Message or the PCM was replaced and requires calibration, no screen may appear. This is not a concern and will not prevent programming updates or being paid for programming updates. 5. Follow all hook-up instructions and continue as prompted to the calibration screen. Typically, a list of calibration numbers will appear. Answer as appropriate for the vehicle and select "Continue." SBDS will then validate the information entered against the information read in the PCM, and any mismatch of software or hardware will be displayed for technician action. 6. Insert the proper calibration or the latest level CD-ROM when prompted and follow the instructions as displayed by SBDS. Do not crank the engine. SBDS will update the engine calibration to the latest level calibration for the selected calibration. 7. After programming is complete, SBDS will display a representation of the Authorized Modification Decal with the Engineering Part Number for the PCM installed. It is important that the label be completed and attached to the vehicle. S8DS will also automatically print a copy of the vehicle log for filing with the Repair Order. 8. Selecting "Continue" will call for a KOEO self test. Any hard faults present after performing self test were not caused by reprogramming. The calibration has now been validated and the PCM is operating properly. Unless directed by other Service Procedures, the vehicle can be released to Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 4171 the customer. PCM REPROGRAMMING WITH SBTS/NGS 1. Select "NGS," then follow procedure "Touring PLM Recalibration." 2. Be sure to use cable with oversized DCL connector. The oversized connector incorporates an 18-volt transformer supplying the required voltage to reprogram the PCM. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-25-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4172 Engine Control Module: Specifications Powertrain Control Module Electrical Connector Bolt 5-7 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4173 Engine Control Module: Locations Engine View The Powertrain Control Module is located at right side of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4176 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4177 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4178 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4179 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4180 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4181 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4182 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4183 Engine Control Module: Connector Views Powertrain Control Module (Part 1 Of 3) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4184 Powertrain Control Module (Part 2 Of 3) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4185 Powertrain Control Module (Part 3 Of 3) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service Precautions > Electronic Component Handling Engine Control Module: Service Precautions Electronic Component Handling STATIC DISCHARGE - Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. - Never touch the PCM connector pins, integrated circuit connector pins, or soldered components on the PCM circuit board. TESTING - When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. - To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE - Do not try to disassemble the control unit. - Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, PCM and radio. - If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECUs. - Avoid getting water on any of the Fuel and Engine Control System Components. Never apply battery power to a component unless directed to do so in a test procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service Precautions > Electronic Component Handling > Page 4188 Engine Control Module: Service Precautions Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. PCM memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service Precautions > Electronic Component Handling > Page 4189 Engine Control Module: Service Precautions Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service Precautions > Page 4190 Engine Control Module: Description and Operation OVERVIEW The Electronic Engine Control (EEC) system provides optimum control of the engine and transmission through the enhanced capability of the Powertrain Control Module (PCM). The EEC system also has an On-board Diagnostics (OBDII) monitoring system with features and functions to meet federal regulations on exhaust emissions. COMPONENTS The EEC system has two major divisions: hardware and software. The hardware includes the PCM, Natural Gas Vehicle (NGV) Module, Constant Control Relay Module (CCRM), Variable Load Control Module (VLCM), sensors, switches, actuators, solenoids, and interconnecting terminals. The software in the PCM provides the strategy control for outputs (engine hardware) based on the values of the inputs to the PCM. OPERATION The PCM receives information from a variety of sensor and switch inputs. Based on the strategy and calibration stored within the memory chip, the PCM generates the appropriate output. The system is designed to minimize emissions and optimize fuel economy and driveability. The software strategy controls the basic operation of the engine and transmission, provides the OBD II strategy, controls the Malfunction Indicator Lamp (MIL), communicates to the scan tool [New Generation Star (NGS), etc.] via the Data Link Connector (DLC), allows for Flash Electrically Erasable/ Programmable Read Only Memory (FEEPROM), provides idle air and fuel trim, and controls Failure Mode Effects Management (FMEM). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Reset Procedure Engine Control Module: Reset Procedure Description The Powertrain Control Module (PCM) Reset allows the scan tool to command the PCM to clear all emission-related diagnostic information. When resetting the PCM, a DTC P1000 will be stored in the PCM until all the OBD II system monitors or components have been tested to satisfy a drive cycle, without any other faults occurring. The following events occur when a PCM reset is performed: - Clears the number of Diagnostic Trouble Codes (DTCs). - Clears the DTCs. - Clears the freeze frame data. - Clears oxygen sensor test data. - Resets status of the OBD II system monitors. - Sets DTC P1000. New Generation STAR (NGS) and Generic Scan Tool Refer to the manufacturer's manual for specific instructions on how to perform PCM reset. Resetting Keep Alive Random Access Memory (RAM) Disconnect the battery ground cable for a minimum of 5 minutes. Resetting Keep Alive RAM will clear learned values the PCM has stored for adaptive systems such as idle and fuel trim. After Keep Alive RAM has been reset, the vehicle may exhibit certain driveability concerns. It will be necessary to drive the vehicle to allow the PCM to relearn values for optimum driveability and performance. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Reset Procedure > Page 4193 Engine Control Module: Removal and Replacement REMOVAL 1. Remove the battery and battery tray. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Loosen the PCM electrical connector bolt and separate the PCM electrical connectors. 3. Remove the RH front door scuff plate. 4. Remove the RH cowl side trim panel. 5. Release the PCM bracket clip. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Reset Procedure > Page 4194 6. Remove the PCM. INSTALLATION To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications Engine Temperature Sensor: Specifications Cylinder Head Temperature (CHT) Sensor 25 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 4198 Engine Temperature Sensor: Locations Engine View The Cylinder Head Temperature Sensor is located at top front of the engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 4199 Engine Temperature Sensor: Description and Operation FEATURES The Cylinder Head Temperature (CHT) sensor: - Is mounted into the wall of the cylinder head and is not connected to any coolant passages. Sends a signal to the PCM indicating the cylinder head temperature. - If the temperature exceeds: 130°C (265°F) the PCM disables four fuel injectors at a time. The PCM will alternate which four injectors are disabled every 32 engine cycles. The four cylinders that are not being fuel injected act as air pumps to aid in cooling the engine. - If the temperature exceeds: 166°C (330°F) the PCM disables all of the fuel injectors until the engine temperature drops below: 153°C (308°F) - If the engine reaches critical temperature, the following happens: - The coolant temperature gauge pointer will read fully hot at 121°C (250°F). - The check gauge warning indicator will illuminate. - DTCs are set. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 4200 Engine Temperature Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the Cylinder Head Temperature (CHT) sensor. 1 Disconnect the electrical connector. 2 Remove the CHT sensor. INSTALLATION 1. Install the CHT. 2. Install the intake manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure (FTP) Sensor PURPOSE The Fuel Tank Pressure (FTP) sensor (A) is used to monitor the fuel tank pressure or vacuum during the OBD II purge monitor test of the Evaporative Emission System for Running Loss vehicles (passenger cars with fuel vapor control valves and trucks with fuel vapor valves). This monitor also performs a fuel system integrity check to determine if there is an evaporative emission system leak. Variations in pressure will be converted into an analog voltage input signal to the PCM. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications Idle Speed/Throttle Actuator - Electronic: Specifications Idle Air Control Valve Bolts (Step 1) 8-10 Nm Idle Air Control Valve Bolts (Step 2) 10-11 Nm Splash Shield Bolts 5.9-8.1 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 4207 Idle Speed/Throttle Actuator - Electronic: Locations The Idle Air Control Valve (IAC) is mounted to the upper intake manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 4208 Idle Speed/Throttle Actuator - Electronic: Description and Operation Purpose The Idle Air Control (IAC) valve is used to control engine idle speed and dashpot functions. Operation The idle air control valve allows air to bypass the throttle plate. The amount of air allowed to bypass the throttle plate, will be determined by the PCM and be controlled by a duty cycle signal. CAUTION: Cleaning the IAC valve is NOT recommended. The use of solvents may damage the IAC valve. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Service and Repair > Installation Idle Speed/Throttle Actuator - Electronic: Service and Repair Installation INSTALLATION NOTE:A new IAC valve gasket must be installed. 1. Install the IAC valve. 1 Position the IAC valve and gasket. 2 Install the bolts in two stages: 8-10 Nm (71-89 in lb) - 10-11 Nm (89-95 in lb) 2. Connect the throttle bypass hose and the IAC electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Service and Repair > Installation > Page 4211 3. Install the accelerator control splash shield. 4. Connect the battery ground cable Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Service and Repair > Installation > Page 4212 Idle Speed/Throttle Actuator - Electronic: Service and Repair Removal REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Remove the accelerator control splash shield. 1 Remove the accelerator splash shield bolts. 2 Remove the accelerator control splash shield from the vehicle. 3. Remove the Idle Air Control (IAC) valve. 1 Disconnect the electrical connector. 2 Disconnect the throttle bypass hose. 3 Remove the bolts. 4 Remove the IAC valve. 5 Remove and discard the IAC valve gasket. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions Information Bus: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4217 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4218 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4219 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4220 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4221 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4222 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4223 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4224 Multiplex Communication Network Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 4225 Information Bus: Description and Operation The module communications network consists of the following: ^ Powertrain Control Module (PCM). ^ Integrated Air Bag Diagnostic Monitor (IABM). ^ Passive Anti-Theft System (PATS) Module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 4226 ^ Generic Electronic Module (GEM). ^ Remote Anti-Theft Personality (RAP) Module. ^ Rear Air Suspension (RAS) Module/4-Wheel Air Suspension (4WAS). ^ 4-Wheel Anti-Lock Brake System (4WABS) Module. The vehicle has two module communications networks. The Powertrain Control Module (PCM) is connected to the Standard Corporate Protocol (SCP) which is an unshielded twisted pair cable (Data Bus Plus, circuit 914 (T/O) and Data Bus Minus, circuit 915 [PK/LB]). The Integrated Air Bag Module (IABM) and any of the optional modules are connected to the ISO 9141 Link via a single wire (circuit 70 [LB/W]). Both networks can be connected to the New Generation STAR (NGS) tester at one connector called the Data Link Connector (DLC). This makes troubleshooting these systems easier by allowing one smart tester to be able to diagnose and control any module on the two networks from one connector. The DLC can be found under the instrument panel between the steering column and the radio. The diagnostic communication network does not permit inter-module communication. When the NGS tester communicates to modules on the diagnostic communication network, the NGS tester must ask for all information; the modules cannot initiate communications. Fault Tolerance Of The SCP The Standard Corporate Protocol (SCP) will remain operational even with the severing of one of the bus wires. Communications will also continue if one of the bus wires is shorted to ground or battery positive voltage (B+) or a termination resistor is lost. This faulted condition is detected and reported to the host by the module's network bus interface circuits. Fault Tolerance Of The Diagnostic Communications Network Unlike the Standard Corporate Protocol (SCP), the ISO 9141 Link will not function if the wire is shorted to ground or battery positive voltage (B+). Also, if one of the modules on the diagnostic communication network loses power or shorts internally, communications to that module will fail. Module Description The Powertrain Control Module (PCM) is on the multiplex communication network. The PCM controls the engine for better fuel economy, emissions control, and failure mode detection and storage. The air bag diagnostic monitor is on the diagnostic communication network. The air bag diagnostic monitor controls the deployment of the air bags based on sensor input. The Generic Electronic Module (GEM) is on the diagnostic communication network. The GEM controls a variety of systems: ^ Windshield wipers. ^ Courtesy lamps. ^ 4-wheel shift on the fly. ^ Warning chimes. ^ One touch down power windows. The Remote Anti-Theft Personality (RAP) is on the diagnostic communication network. The RAP module controls the remote entry, interior lamps, and panic alarm from the keyless entry remote. The Four-Wheel Anti-Lock Brake System (4WABS) is on the diagnostic communication network. The 4WABS controls the brake pressure to the four wheels to keep the vehicle under control while braking. The Passive Anti-Theft System (PATS) module is on the multiplex communication network. The PATS module contains circuitry to connect the vehicle electrical system, the transceiver module, the vehicle module communications network, and the vehicle theft indicator located in the instrument cluster. The PATS module uses a microprocessor to control the system functions. The PATS module microprocessor stores the ignition key codes in non-volatile memory. The PATS module can be diagnosed through the data link connector. The following describes the rear and four wheel air suspension modules. ^ A microcontroller-based electronic module controls the air compressor motor (through a solid state relay) and all system solenoids. The module also provides power to front and rear height sensors. The module controls vehicle height adjustments by monitoring: two height sensors, vehicle speed, a steering sensor, acceleration input, the door ajar signal, transfer case signals, and the brake switch. The module also conducts all fail-safe and diagnostic strategies and contains self test and communication software for testing of the vehicle and module. The control module is mounted in the passenger compartment inside the instrument panel above the radio and temperature controls. The air suspension system control module monitors and controls the system through a 32-pin two-way connector. It is keyed so that the control module cannot be plugged into an incorrect harness. There are two sides of the harness connection to the module. Each is uniquely colored and keyed to prevent reversal of connections. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis Information Bus: Flow of Diagnosis 1. Verify the customer concern by operating the system in question. 2. Visually inspect for obvious signs of electrical damage. Electrical ^ Damaged wiring harness. ^ Loose or corroded connections. ^ Damaged 4-Wheel Anti-Lock Brake System (4WABS) module. ^ Damaged Remote Anti-Theft Personality (RAP) module. ^ Damaged Generic Electronic Module (GEM). ^ Damaged Integrated Air Bag Module (IABM). ^ Damaged Powertrain Control Module (PCM). 3. If the concern is not visually evident, perform the System Precheck. See: Initial Inspection and Diagnostic Overview/System Precheck Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4229 Information Bus: Initial Inspection and Diagnostic Overview Inspection and Verification (Start Here) 1. Verify the customer concern by operating the system in question. 2. Visually inspect for obvious signs of electrical damage. Electrical ^ Damaged wiring harness. ^ Loose or corroded connections. ^ Damaged 4-Wheel Anti-Lock Brake System (4WABS) module. ^ Damaged Remote Anti-Theft Personality (RAP) module. ^ Damaged Generic Electronic Module (GEM). ^ Damaged Integrated Air Bag Module (IABM). ^ Damaged Powertrain Control Module (PCM). 3. If the concern is not visually evident, perform the System Precheck. See: System Precheck Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4230 Information Bus: Diagnostic Trouble Code Tests and Associated Procedures 4-Wheel Air Suspension (4WAS) DTC Reference Chart Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4231 4-Wheel Air Suspension (4WAS) DTC Reference Chart (part 1 Of 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4232 4-Wheel Air Suspension (4WAS) DTC Reference Chart (part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4233 Generic Electronic Module (GEM) DTC Reference Chart Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4234 Generic Electronic Module (GEM) DTC Reference Chart (part 1 Of 4) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4235 Generic Electronic Module (GEM) DTC Reference Chart (part 2 Of 4) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4236 Generic Electronic Module (GEM) DTC Reference Chart (part 3 Of 4) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4237 Generic Electronic Module (GEM) DTC Reference Chart (part 4 Of 4) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4238 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4239 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4240 Information Bus: Pinpoint Tests Pinpoint Test Icons Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4241 A: 4-Wheel A-Lock Brake No Response to NGS Tester A1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4242 A2-A4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4243 A5 B: Remote Anti-Theft No Response to NGS Tester B1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4244 B2-B4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4245 B5 C: GEM No Response to NGS C1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4246 C2-C3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4247 D1-D3 E: 4-Wheel Air Suspension No Response to NGS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4248 E1-E3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4249 E4 F: Powertrain Control Module No Response to NGS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4250 F1-F2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4251 F3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4252 F4-F5 G: PATS Module Does Not Respond to The NGS Tester Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4253 G1 G2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4254 G3-G4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4255 G5-G6 H: No Module/Network Communication on SCP Circuit Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4256 H1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4257 H2-H4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4258 H5-H6 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4259 H7-H8 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4260 H9-H10 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4261 H11-H12 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4262 H13-H15 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4263 H16-H17 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4264 H18-H19 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4265 H20-H21 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4266 H22-H23 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4267 H24-H25 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4268 H26-H27 J: No Module/Network Communication ISO 9140 Circuit Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4269 J1-J3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4270 J4-J5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4271 J6-J7 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4272 J8-J9 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4273 J10-J11 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4274 J12-J13 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4275 J14-J15 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4276 J16-J17 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4277 J18 K: No Module/Network Communication K1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4278 K2-K3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4279 K4-K6 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor 20-27 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 4283 Knock Sensor: Description and Operation The knock sensor is located in the lifter valley and: - Sends a signal to the PCM indicating engine detonation. - If detonation is occurring, the PCM then changes engine timing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 4284 Knock Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the Knock Sensor (KS) . 1 Disconnect the electrical connector. 2 Remove the KS. INSTALLATION 1. Install the Knock Sensor (KS) 1 Install the KS. 2 Connect the electrical connector. 2. Install the intake manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4288 Power Distribution Box The Powertrain Control Module (EEC) Power Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Testing and Inspection Malfunction Indicator Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns Oxygen Sensor: Customer Interest PCM - MIL ON/Multiple DTC's Set/Driveability Concerns Article No. 97-26-19 12/22/97 ^ HESITATION/SURGE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ MALFUNCTION INDICATOR LAMP (MIL) - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 ^ ROUGH IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ STALL - LOW SPEEDS AND OR IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 F-350, NAVIGATOR This TSB article is being republished in its entirety to correct the PCM Application Chart and include a reference to TSB 97-26-17. CALIBRATION: 7-46D-R07, 7-46E-R07, 7-46F-R07, 7-46R-R07, 7-46T-R07, 7-46U-R07, 7-46F-R10, 7-46U-R10, 7-48J-R05, 7-48U-R05, 7-48J-R10, 7-48U-R10, 8-46D-R05, 8-46E-R05, 8-46F-R05, 8-46R-RO5, 8-46T-R05, 8-46U-R05, 8-48J-R05 WARNING: THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS. ISSUE: The Malfunction Indicator Lamp (MIL) may illuminate on vehicles with a 4.6L or 5.4L engine, and one or more of the following concerns may be present: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 4300 ^ MIL lamp on with Diagnostic Trouble Codes (DTCs): P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 ^ Rough idle ^ Engine miss ^ Hesitation/Surge ^ Buck/Jerk ^ Stall at idle ^ Near stall ^ Stall at low speeds This may be caused by the Heated Exhaust Gas Oxygen (HEGO) monitor calibration not allowing enough time for proper monitoring. ACTION: Reprogram the Powertrain Control Module (PCM) and replace the HEGO sensor(s). Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal diagnostics as outlined in the 1997 Powertrain Control/Emissions Diagnosis (PC/ED) On-Board Diagnostics II (OBD-II) Service Manual and repair as required. 2. If the concern still exists or no problems were found, reprogram the PCM using Service Bay Diagnostic System (SDBS) or New Generation Star (NGS) Tester. Refer to the following Recalibration Cross Reference Chart for correct PCM calibration. 3. Replace the HEGO sensor(s) (F88z-9F472-AB) as required. NOTE: FOR 5.4L APPLICATIONS, DEALERS MUST ALSO PERFORM TSB 97-26-17 TO INSTALL THE DRAIN TUBE ON THE LOWER A/C EVAPORATOR DRAIN. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 4301 NOTE: PCM REPLACEMENT IS NOT AUTHORIZED BY THIS TSB. REFER TO THE POWERTRAIN CONTROL/EMISSIONS DIAGNOSIS (PC/ED) SERVICE MANUAL FOR APPROPRIATE DIAGNOSTIC PROCEDURES IF PCM HARDWARE CONCERNS EXIST. Obtain an Authorized Modification Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME F88Z-9F472-AB Heated Exhaust Gas Oxygen (HEGO) Sensor OTHER APPLICABLE ARTICLES: 97-26-17 SUPERSEDES: 97-21-13 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 972619A Reprogram Powertrain 0.2 Hr. Control Module (PCM) 972619DL Replace Heated Exhaust 0.3 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Left Side 972619DR Replace Heated Exhaust 0.6 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Right Side 972619DT Replace Heated Exhaust 0.8 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Both 972619ET Replace Heated Exhaust 0.4 Hr. Gas Oxygen (HEGO) Sensors - 4.6L Both 972619E Replace Heated Exhaust 0.3 Hr. Gas Oxygen (H EGO) Sensors - 4.6L One DEALER CODING CONDITION BASIC PART NO. CODE 9F472 42 OASIS CODES: 607000, 607400, 607700, 608000, 608400, Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 4302 611000, 611500, 612000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4308 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4309 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4310 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4311 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4312 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4313 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4314 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4315 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4316 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4317 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4318 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4319 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4320 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4321 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4322 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns Oxygen Sensor: All Technical Service Bulletins PCM - MIL ON/Multiple DTC's Set/Driveability Concerns Article No. 97-26-19 12/22/97 ^ HESITATION/SURGE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ MALFUNCTION INDICATOR LAMP (MIL) - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 ^ ROUGH IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ STALL - LOW SPEEDS AND OR IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 F-350, NAVIGATOR This TSB article is being republished in its entirety to correct the PCM Application Chart and include a reference to TSB 97-26-17. CALIBRATION: 7-46D-R07, 7-46E-R07, 7-46F-R07, 7-46R-R07, 7-46T-R07, 7-46U-R07, 7-46F-R10, 7-46U-R10, 7-48J-R05, 7-48U-R05, 7-48J-R10, 7-48U-R10, 8-46D-R05, 8-46E-R05, 8-46F-R05, 8-46R-RO5, 8-46T-R05, 8-46U-R05, 8-48J-R05 WARNING: THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS. ISSUE: The Malfunction Indicator Lamp (MIL) may illuminate on vehicles with a 4.6L or 5.4L engine, and one or more of the following concerns may be present: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 4327 ^ MIL lamp on with Diagnostic Trouble Codes (DTCs): P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 ^ Rough idle ^ Engine miss ^ Hesitation/Surge ^ Buck/Jerk ^ Stall at idle ^ Near stall ^ Stall at low speeds This may be caused by the Heated Exhaust Gas Oxygen (HEGO) monitor calibration not allowing enough time for proper monitoring. ACTION: Reprogram the Powertrain Control Module (PCM) and replace the HEGO sensor(s). Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal diagnostics as outlined in the 1997 Powertrain Control/Emissions Diagnosis (PC/ED) On-Board Diagnostics II (OBD-II) Service Manual and repair as required. 2. If the concern still exists or no problems were found, reprogram the PCM using Service Bay Diagnostic System (SDBS) or New Generation Star (NGS) Tester. Refer to the following Recalibration Cross Reference Chart for correct PCM calibration. 3. Replace the HEGO sensor(s) (F88z-9F472-AB) as required. NOTE: FOR 5.4L APPLICATIONS, DEALERS MUST ALSO PERFORM TSB 97-26-17 TO INSTALL THE DRAIN TUBE ON THE LOWER A/C EVAPORATOR DRAIN. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 4328 NOTE: PCM REPLACEMENT IS NOT AUTHORIZED BY THIS TSB. REFER TO THE POWERTRAIN CONTROL/EMISSIONS DIAGNOSIS (PC/ED) SERVICE MANUAL FOR APPROPRIATE DIAGNOSTIC PROCEDURES IF PCM HARDWARE CONCERNS EXIST. Obtain an Authorized Modification Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME F88Z-9F472-AB Heated Exhaust Gas Oxygen (HEGO) Sensor OTHER APPLICABLE ARTICLES: 97-26-17 SUPERSEDES: 97-21-13 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 972619A Reprogram Powertrain 0.2 Hr. Control Module (PCM) 972619DL Replace Heated Exhaust 0.3 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Left Side 972619DR Replace Heated Exhaust 0.6 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Right Side 972619DT Replace Heated Exhaust 0.8 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Both 972619ET Replace Heated Exhaust 0.4 Hr. Gas Oxygen (HEGO) Sensors - 4.6L Both 972619E Replace Heated Exhaust 0.3 Hr. Gas Oxygen (H EGO) Sensors - 4.6L One DEALER CODING CONDITION BASIC PART NO. CODE 9F472 42 OASIS CODES: 607000, 607400, 607700, 608000, 608400, Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 4329 611000, 611500, 612000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4335 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4336 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4337 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4338 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4339 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4340 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4341 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4342 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4343 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4344 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4345 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4346 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4347 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4348 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4349 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 4350 Oxygen Sensor: Specifications Heated Oxygen Sensor 36-46 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > OBD-II Heated Oxygen Sensor Numbering Convention Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > OBD-II Heated Oxygen Sensor Numbering Convention > Page 4353 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4356 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4357 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4358 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4359 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4360 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4361 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4362 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4363 Oxygen Sensor: Connector Views Vehicle Harness Connector Connector Test Pin Numbers Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 4364 HO2S Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 4365 Oxygen Sensor: Description and Operation UPSTREAM HEATED OXYGEN (HO2S) SENSOR: - Has the ability to create a voltage signal dependent on exhaust oxygen content. - Provides feedback information to the PCM used to calculate fuel delivery. - Is positioned in the exhaust manifold outlet. DOWNSTREAM HEATED OXYGEN (HO2S) SENSOR: - Monitors oxygen content after the catalytic converter. - Provides a voltage to the PCM used to calculate catalytic converter integrity. - Is also referred to as the Catalyst Monitor Sensor (CMS). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Upstream Heated Oxygen Sensor Oxygen Sensor: Service and Repair Upstream Heated Oxygen Sensor REMOVAL WARNING: - The normal operating temperature of the exhaust system is very high. never attempt to service any part of the system until it has cooled. Be especially careful when working around the three way catalytic converter. The temperature of the three way catalytic converter rises to a high level after only a few minutes of engine operation. - The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by tuning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. 1. Turn the ignition key off. 2. Disconnect the two Heated Oxygen Sensor (HO2S) electrical connectors. 3. Raise and support the vehicle. 4. Use Oxygen Sensor Wrench to remove the LH and RH HO2Ss. INSTALLATION To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Upstream Heated Oxygen Sensor > Page 4368 Oxygen Sensor: Service and Repair Downstream Heated Oxygen Sensor REMOVAL WARNING: - The normal operating temperature of the exhaust system is very high. Never attempt to service any part of the system until it has cooled. Be especially careful when working around the three way catalytic converter. The temperature of the three way catalytic converter rises to a high level after only a few minutes of engine operation. - The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by tuning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. 1. Turn the ignition key off. 2. Raise and support the vehicle. 3. Remove the Catalyst Monitor Sensor (CMS). 1 Disconnect the electrical connector. 2 Use Oxygen Sensor Wrench to remove the CMS. INSTALLATION To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Page 4369 Oxygen Sensor: Tools and Equipment Oxygen Sensor Wrench T94 - P-9472-A Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision Pressure Feedback Exhaust Sensor: Technical Service Bulletins EGR DPFE Sensor - Voltage Range Revision Article No. 97-22-1 10/27/97 DELTA PRESSURE FEEDBACK EGR (DPFE) - DIAGNOSTIC TIPS FORD: 1994-97 MUSTANG, THUNDERBIRD 1995-97 CONTOUR, CROWN VICTORIA 1996-97 ESCORT, TAURUS LINCOLN-MERCURY: 1990-97 TOWN CAR 1994-97 COUGAR 1995-97 CONTINENTAL, GRAND MARQUIS, MYSTIQUE 1996-97 SABLE, TRACER LIGHT TRUCK: 1994-97 EXPLORER 1995-97 ECONOLINE, F-150-350 SERIES, WINDSTAR 1996-97 AEROSTAR 1997 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: The current DPFE sensor diagnostic reference values as published in the Powertrain Control/Emissions Diagnosis (PC/ED) Service Manual, and also accessed by either the Service Bay Diagnostic System (SBDS) or Service Bay Technical System (SBTS), can lead to the replacement of good DPFE sensors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision > Page 4374 ACTION: Use the following revised DPFE sensor voltage ranges for all (black plastic or aluminum) DPFE system applications when checking the PID (Parameter Identifier Display) value "DPFEGR" or when measuring the DPFE sensor input directly at the breakout box. Refer to Figure 1. NOTE: THESE LISTED VOLTAGE RANGES SHOULD BE USED FOR ALL (BLACK PLASTIC OR ALUMINUM) DPFE SYSTEM APPLICATIONS WHENEVER CHECKING THE PID VALUE "DPFEGR" OR WHEN MEASURING THE DPFE SENSOR INPUT DIRECTLY AT THE BREAKOUT BOX. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4375 Pressure Feedback Exhaust Sensor: Locations Engine View The Differential Pressure Feedback EGR (DPFE) Sensor is located at the right side of engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls General PCM Programming Procedures Engine Control Module: Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls General PCM Programming Procedures > Page 4381 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls General PCM Programming Procedures > Page 4382 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls General PCM Programming Procedures > Page 4383 Engine Control Module: Technical Service Bulletins PCM - Reprogramming Out of Vehicle Article No. 99-4-3 03/08/99 REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V VEHICLES ONLY FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97 PROBE 1996-99 CONTOUR, ESCORT, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to update the affected vehicles and to include an Application Chart for the affected vehicles. ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain reasonably priced, timely PCM programming services at dealerships. Ford has released an out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are reprogrammable to update calibration levels or to reprogram a common hardware type to a new calibration in order to fill a service need without ordering a new PCM. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls General PCM Programming Procedures > Page 4384 ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to have modules updated to new calibrations through the Parts Department instead of ordering new parts. Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the module. An aftermarket service center may bring a module to a dealership for a calibration update or may request an updated calibration be installed to a new service part. The EPA regulations require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a calibration on a PCM out of the vehicle. The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector. The proper calibration must be downloaded to the Data Transfer Card through Service Bay Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is connected, follow the calibration download instructions displayed on the NGS screen. The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling 1-800-ROTUNDA. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-26-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 206000, 290000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls General PCM Programming Procedures > Page 4385 Engine Control Module: Technical Service Bulletins PCM - Reprogramming Tips Article No. 97-9-8 04/28/97 POWERTRAIN CONTROL MODULE - REPROGRAM POWERTRAIN CONTROL MODULE (PCM) - SERVICE PROCEDURES - SERVICE TIP FORD: 1994-97 CROWN VICTORIA, MUSTANG, THUNDERBIRD 1996-97 CONTOUR, ESCORT, PROBE, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR, GRAND MARQUIS 1995-97 CONTINENTAL, TOWN CAR 1996-97 MARK VIII, MYSTIQUE, SABLE, TRACER LIGHT TRUCK: 1994-97 ECONOLINE, F-150-350 SERIES 1995-97 RANGER 1995-98 WINDSTAR 1996 BRONCO 1996-97 AEROSTAR, EXPLORER 1997 EXPEDITION, MOUNTAINEER This TSB article is being republished in its entirety to include Windstar. ISSUE: Powertrain Control Modules (PCMs) no longer need to be replaced when servicing driveability concerns. The only time a PCM needs replacing is when it can no longer be reprogrammed and/or is damaged. In all other cases, the PCM must be reprogrammed and NOT REPLACED. ACTION: Use the following Service Procedure to properly reprogram a PCM. SERVICE PROCEDURE PCM REPROGRAMMING USING SBDS 1. At the Main menu, select Powertrain and enter the Vehicle Identification Number (VIN). Select "Continue." 2. From the Powertrain menu, select Electronic Engine category. 3. Scroll through the "Tool List" to PCM Reprogramming and select "Continue." 4. Any TSBs or Recalls for the entered vehicle will be displayed. There is up to a 6 week delay for TSB/Recall information updates on SBDS. New TSBs/Recalls may not appear or only the TSB number will be displayed even though the new calibration is on the current calibration CD-ROM. Also, if the vehicle calibration is being updated because of a Special Service Message, Broadcast Message or the PCM was replaced and requires calibration, no screen may appear. This is not a concern and will not prevent programming updates or being paid for programming updates. 5. Follow all hook-up instructions and continue as prompted to the calibration screen. Typically, a list of calibration numbers will appear. Answer as appropriate for the vehicle and select "Continue." SBDS will then validate the information entered against the information read in the PCM, and any mismatch of software or hardware will be displayed for technician action. 6. Insert the proper calibration or the latest level CD-ROM when prompted and follow the instructions as displayed by SBDS. Do not crank the engine. SBDS will update the engine calibration to the latest level calibration for the selected calibration. 7. After programming is complete, SBDS will display a representation of the Authorized Modification Decal with the Engineering Part Number for the PCM installed. It is important that the label be completed and attached to the vehicle. S8DS will also automatically print a copy of the vehicle log for filing with the Repair Order. 8. Selecting "Continue" will call for a KOEO self test. Any hard faults present after performing self test were not caused by reprogramming. The calibration has now been validated and the PCM is operating properly. Unless directed by other Service Procedures, the vehicle can be released to Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls General PCM Programming Procedures > Page 4386 the customer. PCM REPROGRAMMING WITH SBTS/NGS 1. Select "NGS," then follow procedure "Touring PLM Recalibration." 2. Be sure to use cable with oversized DCL connector. The oversized connector incorporates an 18-volt transformer supplying the required voltage to reprogram the PCM. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-25-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4387 Engine Control Module: Specifications Powertrain Control Module Electrical Connector Bolt 5-7 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4388 Engine Control Module: Locations Engine View The Powertrain Control Module is located at right side of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4391 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4392 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4393 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4394 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4395 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4396 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4397 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4398 Engine Control Module: Connector Views Powertrain Control Module (Part 1 Of 3) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4399 Powertrain Control Module (Part 2 Of 3) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4400 Powertrain Control Module (Part 3 Of 3) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service Precautions > Electronic Component Handling Engine Control Module: Service Precautions Electronic Component Handling STATIC DISCHARGE - Discharge any static electrical charges before handling electronic parts by touching ground or maintaining a ground connection to a bare skin area like the wrist. - Never touch the PCM connector pins, integrated circuit connector pins, or soldered components on the PCM circuit board. TESTING - When measuring voltage at the control unit harness connector, disconnect harness connector with the ignition OFF, then turn ignition "ON" as necessary. - To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin. CONTROL UNIT DAMAGE - Do not try to disassemble the control unit. - Before performing electrical welding (for instance, spot welding), disconnect the battery, climate control, injection, cruise control, PCM and radio. - If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECUs. - Avoid getting water on any of the Fuel and Engine Control System Components. Never apply battery power to a component unless directed to do so in a test procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service Precautions > Electronic Component Handling > Page 4403 Engine Control Module: Service Precautions Electronic Component Replacement 1. Before servicing electronic components, disconnect the battery ground. NOTE: Before removing battery ground, access trouble codes. PCM memory will be erased if ground cable is removed. 2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service Precautions > Electronic Component Handling > Page 4404 Engine Control Module: Service Precautions Electrostatic Discharge ELECTROSTATIC DISCHARGE Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature. There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. CHARGING BY FRICTION Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. CHARGING BY INDUCTION Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. PRECAUTIONS Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service Precautions > Page 4405 Engine Control Module: Description and Operation OVERVIEW The Electronic Engine Control (EEC) system provides optimum control of the engine and transmission through the enhanced capability of the Powertrain Control Module (PCM). The EEC system also has an On-board Diagnostics (OBDII) monitoring system with features and functions to meet federal regulations on exhaust emissions. COMPONENTS The EEC system has two major divisions: hardware and software. The hardware includes the PCM, Natural Gas Vehicle (NGV) Module, Constant Control Relay Module (CCRM), Variable Load Control Module (VLCM), sensors, switches, actuators, solenoids, and interconnecting terminals. The software in the PCM provides the strategy control for outputs (engine hardware) based on the values of the inputs to the PCM. OPERATION The PCM receives information from a variety of sensor and switch inputs. Based on the strategy and calibration stored within the memory chip, the PCM generates the appropriate output. The system is designed to minimize emissions and optimize fuel economy and driveability. The software strategy controls the basic operation of the engine and transmission, provides the OBD II strategy, controls the Malfunction Indicator Lamp (MIL), communicates to the scan tool [New Generation Star (NGS), etc.] via the Data Link Connector (DLC), allows for Flash Electrically Erasable/ Programmable Read Only Memory (FEEPROM), provides idle air and fuel trim, and controls Failure Mode Effects Management (FMEM). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Reset Procedure Engine Control Module: Reset Procedure Description The Powertrain Control Module (PCM) Reset allows the scan tool to command the PCM to clear all emission-related diagnostic information. When resetting the PCM, a DTC P1000 will be stored in the PCM until all the OBD II system monitors or components have been tested to satisfy a drive cycle, without any other faults occurring. The following events occur when a PCM reset is performed: - Clears the number of Diagnostic Trouble Codes (DTCs). - Clears the DTCs. - Clears the freeze frame data. - Clears oxygen sensor test data. - Resets status of the OBD II system monitors. - Sets DTC P1000. New Generation STAR (NGS) and Generic Scan Tool Refer to the manufacturer's manual for specific instructions on how to perform PCM reset. Resetting Keep Alive Random Access Memory (RAM) Disconnect the battery ground cable for a minimum of 5 minutes. Resetting Keep Alive RAM will clear learned values the PCM has stored for adaptive systems such as idle and fuel trim. After Keep Alive RAM has been reset, the vehicle may exhibit certain driveability concerns. It will be necessary to drive the vehicle to allow the PCM to relearn values for optimum driveability and performance. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Reset Procedure > Page 4408 Engine Control Module: Removal and Replacement REMOVAL 1. Remove the battery and battery tray. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Loosen the PCM electrical connector bolt and separate the PCM electrical connectors. 3. Remove the RH front door scuff plate. 4. Remove the RH cowl side trim panel. 5. Release the PCM bracket clip. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Reset Procedure > Page 4409 6. Remove the PCM. INSTALLATION To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4413 Power Distribution Box The Powertrain Control Module (EEC) Power Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4423 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4424 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4430 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4431 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement Air Flow Meter/Sensor: All Technical Service Bulletins Mass Air Flow Sensor - Assembly Replacement Article No. 96-22-5 10/21/96 MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP FORD: 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR, EXPLORER, RANGER 1993-97 VILLAGER 1994-96 BRONCO 1994-97 ECONOLINE 1995-97 F-150, WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: The Mass Air Flow (MAF) sensor is not designed to be removed from its body (die-cast or plastic) for servicing. The sensing elements located inside the by-pass tube can be damaged by poking/probing/touching. ACTION: Service the MAF sensor as an assembly (refer to Figure 1). WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement > Page 4436 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement Air Flow Meter/Sensor: All Technical Service Bulletins Mass Air Flow Sensor - Assembly Replacement Article No. 96-22-5 10/21/96 MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP FORD: 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR, EXPLORER, RANGER 1993-97 VILLAGER 1994-96 BRONCO 1994-97 ECONOLINE 1995-97 F-150, WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: The Mass Air Flow (MAF) sensor is not designed to be removed from its body (die-cast or plastic) for servicing. The sensing elements located inside the by-pass tube can be damaged by poking/probing/touching. ACTION: Service the MAF sensor as an assembly (refer to Figure 1). WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement > Page 4442 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 4443 Air Flow Meter/Sensor: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 4444 RH Component The Mass Air Flow Sensor is located in air cleaner assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 4445 Air Flow Meter/Sensor: Description and Operation PURPOSE The Mass Air Flow (MAF) sensor: - Sends the PCM a signal indicating mass airflow rate of air entering the engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal Air Flow Meter/Sensor: Service and Repair Removal REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Open the engine air cleaner. - Disconnect the Mass Air Flow (MAF) sensor connector from the wiring harness. - Release the air cleaner clamp. Separate the inlet side of the air cleaner from the outlet side of the air cleaner. 3. Cut the tape on the wire loom of the extension harness. CAUTION: Do not cut the MAF sensor wires when cutting the tape on the wire loom. - Peel back the wire loom from the extension harness near the grommet in the air cleaner. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal > Page 4448 4. Remove the grommet from the outlet side of the air cleaner and slide the grommet down the extension harness. 5. Remove the MAF sensor plate and MAF sensor from the outlet side of the engine air cleaner. 6. Disconnect the MAF sensor electrical connector. 7. Remove the nuts and separate the MAF plate from the MAF sensor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal > Page 4449 Air Flow Meter/Sensor: Service and Repair Installation INSTALLATION CAUTION: - Do not tamper with the MAF sensing elements located in the airflow bypass; tampering may result in unit failure. - The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. NOTE: - Use the alignment notch to properly align the inlet side and the outlet side of the engine air cleaner. - The MAF sensor module and body are calibrated and replaced as a unit. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt 8-12 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 4453 Camshaft Position Sensor: Locations Engine View The Camshaft Position Sensor is located in front of the engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 4454 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 4455 Camshaft Position Sensor: Description and Operation The Camshaft Position (CMP) sensor: - Sends the PCM a signal indicating camshaft position, which is used for fuel synchronization. NOTE: The Camshaft Position (CMP) sensor is also referred to as Cylinder Identification Sensor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 4456 Camshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the CMP sensor. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Coolant Temperature Sensor Coolant Temperature Sensor/Switch (For Computer): Locations Coolant Temperature Sensor Engine View The Engine Coolant Temperature Sensor is located in front of the engine. NOTE: In some applications of the 4.6L engine, the Cylinder Head Temperature (CHT) sensor provides the signal used by the Powertrain Control Module (PCM) in place of the Coolant Temperature Sensor (CTS) for functions such as, but not limited to, activating the electric cooling fans. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Coolant Temperature Sensor > Page 4461 Engine Views Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4462 Coolant Temperature Sensor/Switch (For Computer): Description and Operation The Engine Coolant Temperature (ECT) sensor: - Sends the PCM a signal indicating engine temperature. - Resistance decreases as coolant temperature increases. NOTE: In some applications of the 4.6L engine, the Cylinder Head Temperature (CHT) sensor provides the signal used by the Powertrain Control Module (PCM) in place of the Coolant Temperature Sensor (CTS) for functions such as, but not limited to, activating the electric cooling fans. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4463 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Partially drain the cooling system. 3. Remove the Engine Coolant Temperature (ECT) sensor . 1 Disconnect the electrical connector. 2 Remove the ECT sensor. INSTALLATION 1. Install the ECT. 2. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Retainer Torque 8-12 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 4467 Crankshaft Position Sensor: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 4468 The Crankshaft Position Sensor is located at the lower front of engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 4469 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) sensor: - Sends the PCM a signal indicating crankshaft position. - Is essential for calculating spark timing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 4470 Crankshaft Position Sensor: Service and Repair REMOVAL WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 3. Release the tension on the accessory drive belt. 1. Remove the A/C compressor. 1 Remove the A/C compressor bolts. 2 Remove the A/C compressor and position aside. NOTE: Do not remove lines from the A/C compressor. 5. Remove the (A) CKP sensor bolt and the (B) CKP sensor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 4471 To install, reverse the removal procedure NOTE:If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications Engine Temperature Sensor: Specifications Cylinder Head Temperature (CHT) Sensor 25 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 4475 Engine Temperature Sensor: Locations Engine View The Cylinder Head Temperature Sensor is located at top front of the engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 4476 Engine Temperature Sensor: Description and Operation FEATURES The Cylinder Head Temperature (CHT) sensor: - Is mounted into the wall of the cylinder head and is not connected to any coolant passages. Sends a signal to the PCM indicating the cylinder head temperature. - If the temperature exceeds: 130°C (265°F) the PCM disables four fuel injectors at a time. The PCM will alternate which four injectors are disabled every 32 engine cycles. The four cylinders that are not being fuel injected act as air pumps to aid in cooling the engine. - If the temperature exceeds: 166°C (330°F) the PCM disables all of the fuel injectors until the engine temperature drops below: 153°C (308°F) - If the engine reaches critical temperature, the following happens: - The coolant temperature gauge pointer will read fully hot at 121°C (250°F). - The check gauge warning indicator will illuminate. - DTCs are set. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 4477 Engine Temperature Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the Cylinder Head Temperature (CHT) sensor. 1 Disconnect the electrical connector. 2 Remove the CHT sensor. INSTALLATION 1. Install the CHT. 2. Install the intake manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure (FTP) Sensor PURPOSE The Fuel Tank Pressure (FTP) sensor (A) is used to monitor the fuel tank pressure or vacuum during the OBD II purge monitor test of the Evaporative Emission System for Running Loss vehicles (passenger cars with fuel vapor control valves and trucks with fuel vapor valves). This monitor also performs a fuel system integrity check to determine if there is an evaporative emission system leak. Variations in pressure will be converted into an analog voltage input signal to the PCM. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 4484 Engine View The Intake Air Temperature Sensor is located on the air intake tube. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 4485 Intake Air Temperature Sensor: Description and Operation PURPOSE The Intake Air Temperature (IAT) sensor: - Sends the PCM a signal indicating the temperature of the air entering the engine. - It's resistance decreases as temperature increases. - The PCM uses the air temperature information as a correction factor in the calculation of fuel, spark and MAF. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 4486 Intake Air Temperature Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 3. Remove the IAT sensor. INSTALLATION To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor 20-27 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 4490 Knock Sensor: Description and Operation The knock sensor is located in the lifter valley and: - Sends a signal to the PCM indicating engine detonation. - If detonation is occurring, the PCM then changes engine timing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 4491 Knock Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the Knock Sensor (KS) . 1 Disconnect the electrical connector. 2 Remove the KS. INSTALLATION 1. Install the Knock Sensor (KS) 1 Install the KS. 2 Connect the electrical connector. 2. Install the intake manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns Oxygen Sensor: Customer Interest PCM - MIL ON/Multiple DTC's Set/Driveability Concerns Article No. 97-26-19 12/22/97 ^ HESITATION/SURGE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ MALFUNCTION INDICATOR LAMP (MIL) - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 ^ ROUGH IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ STALL - LOW SPEEDS AND OR IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 F-350, NAVIGATOR This TSB article is being republished in its entirety to correct the PCM Application Chart and include a reference to TSB 97-26-17. CALIBRATION: 7-46D-R07, 7-46E-R07, 7-46F-R07, 7-46R-R07, 7-46T-R07, 7-46U-R07, 7-46F-R10, 7-46U-R10, 7-48J-R05, 7-48U-R05, 7-48J-R10, 7-48U-R10, 8-46D-R05, 8-46E-R05, 8-46F-R05, 8-46R-RO5, 8-46T-R05, 8-46U-R05, 8-48J-R05 WARNING: THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS. ISSUE: The Malfunction Indicator Lamp (MIL) may illuminate on vehicles with a 4.6L or 5.4L engine, and one or more of the following concerns may be present: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 4500 ^ MIL lamp on with Diagnostic Trouble Codes (DTCs): P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 ^ Rough idle ^ Engine miss ^ Hesitation/Surge ^ Buck/Jerk ^ Stall at idle ^ Near stall ^ Stall at low speeds This may be caused by the Heated Exhaust Gas Oxygen (HEGO) monitor calibration not allowing enough time for proper monitoring. ACTION: Reprogram the Powertrain Control Module (PCM) and replace the HEGO sensor(s). Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal diagnostics as outlined in the 1997 Powertrain Control/Emissions Diagnosis (PC/ED) On-Board Diagnostics II (OBD-II) Service Manual and repair as required. 2. If the concern still exists or no problems were found, reprogram the PCM using Service Bay Diagnostic System (SDBS) or New Generation Star (NGS) Tester. Refer to the following Recalibration Cross Reference Chart for correct PCM calibration. 3. Replace the HEGO sensor(s) (F88z-9F472-AB) as required. NOTE: FOR 5.4L APPLICATIONS, DEALERS MUST ALSO PERFORM TSB 97-26-17 TO INSTALL THE DRAIN TUBE ON THE LOWER A/C EVAPORATOR DRAIN. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 4501 NOTE: PCM REPLACEMENT IS NOT AUTHORIZED BY THIS TSB. REFER TO THE POWERTRAIN CONTROL/EMISSIONS DIAGNOSIS (PC/ED) SERVICE MANUAL FOR APPROPRIATE DIAGNOSTIC PROCEDURES IF PCM HARDWARE CONCERNS EXIST. Obtain an Authorized Modification Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME F88Z-9F472-AB Heated Exhaust Gas Oxygen (HEGO) Sensor OTHER APPLICABLE ARTICLES: 97-26-17 SUPERSEDES: 97-21-13 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 972619A Reprogram Powertrain 0.2 Hr. Control Module (PCM) 972619DL Replace Heated Exhaust 0.3 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Left Side 972619DR Replace Heated Exhaust 0.6 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Right Side 972619DT Replace Heated Exhaust 0.8 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Both 972619ET Replace Heated Exhaust 0.4 Hr. Gas Oxygen (HEGO) Sensors - 4.6L Both 972619E Replace Heated Exhaust 0.3 Hr. Gas Oxygen (H EGO) Sensors - 4.6L One DEALER CODING CONDITION BASIC PART NO. CODE 9F472 42 OASIS CODES: 607000, 607400, 607700, 608000, 608400, Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 4502 611000, 611500, 612000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4508 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4509 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4510 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4511 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4512 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4513 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4514 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4515 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4516 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4517 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4518 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4519 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4520 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4521 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4522 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns Oxygen Sensor: All Technical Service Bulletins PCM - MIL ON/Multiple DTC's Set/Driveability Concerns Article No. 97-26-19 12/22/97 ^ HESITATION/SURGE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ MALFUNCTION INDICATOR LAMP (MIL) - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 ^ ROUGH IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ STALL - LOW SPEEDS AND OR IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 F-350, NAVIGATOR This TSB article is being republished in its entirety to correct the PCM Application Chart and include a reference to TSB 97-26-17. CALIBRATION: 7-46D-R07, 7-46E-R07, 7-46F-R07, 7-46R-R07, 7-46T-R07, 7-46U-R07, 7-46F-R10, 7-46U-R10, 7-48J-R05, 7-48U-R05, 7-48J-R10, 7-48U-R10, 8-46D-R05, 8-46E-R05, 8-46F-R05, 8-46R-RO5, 8-46T-R05, 8-46U-R05, 8-48J-R05 WARNING: THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS. ISSUE: The Malfunction Indicator Lamp (MIL) may illuminate on vehicles with a 4.6L or 5.4L engine, and one or more of the following concerns may be present: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 4527 ^ MIL lamp on with Diagnostic Trouble Codes (DTCs): P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 ^ Rough idle ^ Engine miss ^ Hesitation/Surge ^ Buck/Jerk ^ Stall at idle ^ Near stall ^ Stall at low speeds This may be caused by the Heated Exhaust Gas Oxygen (HEGO) monitor calibration not allowing enough time for proper monitoring. ACTION: Reprogram the Powertrain Control Module (PCM) and replace the HEGO sensor(s). Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal diagnostics as outlined in the 1997 Powertrain Control/Emissions Diagnosis (PC/ED) On-Board Diagnostics II (OBD-II) Service Manual and repair as required. 2. If the concern still exists or no problems were found, reprogram the PCM using Service Bay Diagnostic System (SDBS) or New Generation Star (NGS) Tester. Refer to the following Recalibration Cross Reference Chart for correct PCM calibration. 3. Replace the HEGO sensor(s) (F88z-9F472-AB) as required. NOTE: FOR 5.4L APPLICATIONS, DEALERS MUST ALSO PERFORM TSB 97-26-17 TO INSTALL THE DRAIN TUBE ON THE LOWER A/C EVAPORATOR DRAIN. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 4528 NOTE: PCM REPLACEMENT IS NOT AUTHORIZED BY THIS TSB. REFER TO THE POWERTRAIN CONTROL/EMISSIONS DIAGNOSIS (PC/ED) SERVICE MANUAL FOR APPROPRIATE DIAGNOSTIC PROCEDURES IF PCM HARDWARE CONCERNS EXIST. Obtain an Authorized Modification Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME F88Z-9F472-AB Heated Exhaust Gas Oxygen (HEGO) Sensor OTHER APPLICABLE ARTICLES: 97-26-17 SUPERSEDES: 97-21-13 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 972619A Reprogram Powertrain 0.2 Hr. Control Module (PCM) 972619DL Replace Heated Exhaust 0.3 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Left Side 972619DR Replace Heated Exhaust 0.6 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Right Side 972619DT Replace Heated Exhaust 0.8 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Both 972619ET Replace Heated Exhaust 0.4 Hr. Gas Oxygen (HEGO) Sensors - 4.6L Both 972619E Replace Heated Exhaust 0.3 Hr. Gas Oxygen (H EGO) Sensors - 4.6L One DEALER CODING CONDITION BASIC PART NO. CODE 9F472 42 OASIS CODES: 607000, 607400, 607700, 608000, 608400, Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 4529 611000, 611500, 612000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4535 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4536 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4537 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4538 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4539 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4540 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4541 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4542 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4543 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4544 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4545 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4546 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4547 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4548 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 01-9-7 > May > 01 > Emissions/Engine Controls - Driveability Diagnosis > Page 4549 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 4550 Oxygen Sensor: Specifications Heated Oxygen Sensor 36-46 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > OBD-II Heated Oxygen Sensor Numbering Convention Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > OBD-II Heated Oxygen Sensor Numbering Convention > Page 4553 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4556 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4557 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4558 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4559 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4560 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4561 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4562 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4563 Oxygen Sensor: Connector Views Vehicle Harness Connector Connector Test Pin Numbers Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 4564 HO2S Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 4565 Oxygen Sensor: Description and Operation UPSTREAM HEATED OXYGEN (HO2S) SENSOR: - Has the ability to create a voltage signal dependent on exhaust oxygen content. - Provides feedback information to the PCM used to calculate fuel delivery. - Is positioned in the exhaust manifold outlet. DOWNSTREAM HEATED OXYGEN (HO2S) SENSOR: - Monitors oxygen content after the catalytic converter. - Provides a voltage to the PCM used to calculate catalytic converter integrity. - Is also referred to as the Catalyst Monitor Sensor (CMS). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Upstream Heated Oxygen Sensor Oxygen Sensor: Service and Repair Upstream Heated Oxygen Sensor REMOVAL WARNING: - The normal operating temperature of the exhaust system is very high. never attempt to service any part of the system until it has cooled. Be especially careful when working around the three way catalytic converter. The temperature of the three way catalytic converter rises to a high level after only a few minutes of engine operation. - The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by tuning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. 1. Turn the ignition key off. 2. Disconnect the two Heated Oxygen Sensor (HO2S) electrical connectors. 3. Raise and support the vehicle. 4. Use Oxygen Sensor Wrench to remove the LH and RH HO2Ss. INSTALLATION To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Upstream Heated Oxygen Sensor > Page 4568 Oxygen Sensor: Service and Repair Downstream Heated Oxygen Sensor REMOVAL WARNING: - The normal operating temperature of the exhaust system is very high. Never attempt to service any part of the system until it has cooled. Be especially careful when working around the three way catalytic converter. The temperature of the three way catalytic converter rises to a high level after only a few minutes of engine operation. - The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by tuning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. 1. Turn the ignition key off. 2. Raise and support the vehicle. 3. Remove the Catalyst Monitor Sensor (CMS). 1 Disconnect the electrical connector. 2 Use Oxygen Sensor Wrench to remove the CMS. INSTALLATION To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Page 4569 Oxygen Sensor: Tools and Equipment Oxygen Sensor Wrench T94 - P-9472-A Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision Pressure Feedback Exhaust Sensor: Technical Service Bulletins EGR DPFE Sensor - Voltage Range Revision Article No. 97-22-1 10/27/97 DELTA PRESSURE FEEDBACK EGR (DPFE) - DIAGNOSTIC TIPS FORD: 1994-97 MUSTANG, THUNDERBIRD 1995-97 CONTOUR, CROWN VICTORIA 1996-97 ESCORT, TAURUS LINCOLN-MERCURY: 1990-97 TOWN CAR 1994-97 COUGAR 1995-97 CONTINENTAL, GRAND MARQUIS, MYSTIQUE 1996-97 SABLE, TRACER LIGHT TRUCK: 1994-97 EXPLORER 1995-97 ECONOLINE, F-150-350 SERIES, WINDSTAR 1996-97 AEROSTAR 1997 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: The current DPFE sensor diagnostic reference values as published in the Powertrain Control/Emissions Diagnosis (PC/ED) Service Manual, and also accessed by either the Service Bay Diagnostic System (SBDS) or Service Bay Technical System (SBTS), can lead to the replacement of good DPFE sensors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision > Page 4574 ACTION: Use the following revised DPFE sensor voltage ranges for all (black plastic or aluminum) DPFE system applications when checking the PID (Parameter Identifier Display) value "DPFEGR" or when measuring the DPFE sensor input directly at the breakout box. Refer to Figure 1. NOTE: THESE LISTED VOLTAGE RANGES SHOULD BE USED FOR ALL (BLACK PLASTIC OR ALUMINUM) DPFE SYSTEM APPLICATIONS WHENEVER CHECKING THE PID VALUE "DPFEGR" OR WHEN MEASURING THE DPFE SENSOR INPUT DIRECTLY AT THE BREAKOUT BOX. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4575 Pressure Feedback Exhaust Sensor: Locations Engine View The Differential Pressure Feedback EGR (DPFE) Sensor is located at the right side of engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Retaining Screws 2.8-3.4 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 4579 Throttle Position Sensor: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 4580 The Throttle Position Sensor is attached to the throttle body. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 4581 Throttle Position Sensor: Description and Operation PURPOSE The Throttle Position Sensor (TP): - Sends the PCM a signal indicating the throttle plate angle. - Is the main input to the PCM from the driver. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 4582 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Remove the accelerator control splash shield. 1 Remove three accelerator splash shield bolts. 2 Remove the accelerator control splash shield from the vehicle. 3. Remove the Throttle Position (TP) sensor. 1 Disconnect the electrical connector. 2 Remove the two bolts. 3 Remove the TP sensor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 4583 To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > New Digital Transmission Range Sensor - Service Tip Transmission Position Switch/Sensor: Technical Service Bulletins New Digital Transmission Range Sensor - Service Tip Article No. 96-24-10 11/18/96 TRANSMISSION - E40D - 4R70W - 4R44E - 5R55E - NEW DIGITAL TRANSMISSION RANGE SENSOR - DIAGNOSIS SERVICE TIP LINCOLN-MERCURY: 1997 MARK VIII LIGHT TRUCK: 1997 AEROSTAR, ECONOLINE, EXPEDITION, EXPLORER, F-150, F-250, MOUNTAINEER ISSUE: Beginning with Job 1 1997, some vehicles will be equipped with a new Digital Transmission Range (DTR) sensor. The DTR sensor is located on the outside of the transmission (Figure 1) at the outer manual lever. ACTION: Refer to the following text to properly diagnose a concern with the DTR sensor. The new DTR sensor completes the start circuit in "Park" and "Neutral," the backup lamp circuit in "Reverse" and the neutral sense circuit (4X4 only) in "Neutral." The DTR sensor also opens/closes a set of four (4) switches that are monitored by the Powertrain Control Module (PCM) to determine the position of the transmission manual lever. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > New Digital Transmission Range Sensor - Service Tip > Page 4588 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > New Digital Transmission Range Sensor - Service Tip > Page 4589 To properly diagnose the DTR sensor, use the NGS, Rotunda Transmission Tester with TR/MLP Cable "E" (Figure 2) and the new DTR Sensor Overlay (Figure 4), while following the procedures outlined in the appropriate model 1997 Service Manual, Section 07-01 or appropriate model 1997 Workshop Manual, Section 307-01. The new DTR Sensor Overlay (007-00131) and updated Tester Manual was sent to all dealers in August 1996. The TR/MLP Cable "E" (007-00111) was sent to all dealers in June 1995 (refer to TSB 95-19-7). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > New Digital Transmission Range Sensor - Service Tip > Page 4590 When using Cable "E" (Figure 3) to diagnose the DTR sensor, the slide switch must be in the "Digital" position and the "Black" 12-pin connector installed on the sensor. Having the slide switch in the incorrect position or using the incorrect 12-pin connector will result in misdiagnosis and possible replacement of a good component. For diagnosis of the DTR sensor, always refer to the appropriate model 1997 Service Manual, Section 07.01 or appropriate model 1997 Workshop Manual, Section 3O7-01 for proper procedure and required equipment. OTHER APPLICABLE ARTICLES: 95-19-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 503000, 503300, 504000, 601300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 4591 Transmission Position Switch/Sensor: Specifications TORQUE SPECIFICATIONS DTR Sensor Bolts ................................................................................................................................ ..................................... 7-10 Nm (62-89 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 4592 Transmission Position Switch/Sensor: Locations Transmission View The Digital Transmission Range Sensor is located at left side of the automatic transmission. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 4593 Digital Transmission Range Sensor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 4594 Transmission Position Switch/Sensor: Adjustments NOTE: Use Digital Transmission Range (DTR) Sensor Alignment Tool to align both TR and DTR sensors. 1. Raise and support vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Disconnect the manual lever shift control cable. 3. Disconnect the TR or DTR electrical connector. 4. Remove the manual control lever. (1) Remove the nut. (2) Remove the lever. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. 5. Loosen the TR or DTR bolts. 6. Use DTR sensor alignment tool, to align the DTR or TR sensor slots. NOTE: Manual shift lever must be in the neutral position. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 4595 7. Tighten the DTR or TR sensor bolts. 8. Install the manual control lever. (1) Position the manual control lever. (2) Install a new manual lever shaft outer nut. 9. With the manual lever in overdrive connect the shift lever control cable. 10. Install the DTR sensor electrical connector. 11. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications TORQUE SPECIFICATIONS Vehicle Speed Sensor (VSS) Bolt ........................................................................................................................................ 11-13 Nm (98-115 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 4599 Vehicle Speed Sensor: Locations Transmission View The Vehicle Speed Sensor is located at left rear of transmission. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4602 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4603 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4604 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4605 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4606 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4607 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4608 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 4609 Vehicle Speed Sensor: Description and Operation Purpose The Vehicle Speed (VSS) Sensor: - Is gear driven by the transmission. - Sends a signal to the PCM indicating transmission speed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 4610 Vehicle Speed Sensor: Service and Repair REMOVAL 1. Disconnect the battery. 2. Raise and support the vehicle. WARNING: The electrical power to the air suspension system must be shut OFF prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning OFF the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during 1 these operations. 3. Remove the Vehicle Speed Sensor (VSS). (1) Disconnect the electrical connector. (2) Remove the bolt. (3) Remove the VSS. 4. Remove the Vehicle Speed Sensor (VSS) drive gear. INSTALLATION 1. Install the Vehicle Speed Sensor (VSS) drive gear. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 4611 2. Install the VSS. (1) Install the VSS. (2) Install the bolt. (3) Connect the electrical connector. 3. Remove supports and lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning ON the air suspension switch. 4. Reconnect the battery ground cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Retaining Screws 2.8-3.4 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 4615 Throttle Position Sensor: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 4616 The Throttle Position Sensor is attached to the throttle body. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 4617 Throttle Position Sensor: Description and Operation PURPOSE The Throttle Position Sensor (TP): - Sends the PCM a signal indicating the throttle plate angle. - Is the main input to the PCM from the driver. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 4618 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Remove the accelerator control splash shield. 1 Remove three accelerator splash shield bolts. 2 Remove the accelerator control splash shield from the vehicle. 3. Remove the Throttle Position (TP) sensor. 1 Disconnect the electrical connector. 2 Remove the two bolts. 3 Remove the TP sensor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 4619 To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > New Digital Transmission Range Sensor Service Tip Transmission Position Switch/Sensor: Technical Service Bulletins New Digital Transmission Range Sensor - Service Tip Article No. 96-24-10 11/18/96 TRANSMISSION - E40D - 4R70W - 4R44E - 5R55E - NEW DIGITAL TRANSMISSION RANGE SENSOR - DIAGNOSIS SERVICE TIP LINCOLN-MERCURY: 1997 MARK VIII LIGHT TRUCK: 1997 AEROSTAR, ECONOLINE, EXPEDITION, EXPLORER, F-150, F-250, MOUNTAINEER ISSUE: Beginning with Job 1 1997, some vehicles will be equipped with a new Digital Transmission Range (DTR) sensor. The DTR sensor is located on the outside of the transmission (Figure 1) at the outer manual lever. ACTION: Refer to the following text to properly diagnose a concern with the DTR sensor. The new DTR sensor completes the start circuit in "Park" and "Neutral," the backup lamp circuit in "Reverse" and the neutral sense circuit (4X4 only) in "Neutral." The DTR sensor also opens/closes a set of four (4) switches that are monitored by the Powertrain Control Module (PCM) to determine the position of the transmission manual lever. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > New Digital Transmission Range Sensor Service Tip > Page 4624 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > New Digital Transmission Range Sensor Service Tip > Page 4625 To properly diagnose the DTR sensor, use the NGS, Rotunda Transmission Tester with TR/MLP Cable "E" (Figure 2) and the new DTR Sensor Overlay (Figure 4), while following the procedures outlined in the appropriate model 1997 Service Manual, Section 07-01 or appropriate model 1997 Workshop Manual, Section 307-01. The new DTR Sensor Overlay (007-00131) and updated Tester Manual was sent to all dealers in August 1996. The TR/MLP Cable "E" (007-00111) was sent to all dealers in June 1995 (refer to TSB 95-19-7). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > New Digital Transmission Range Sensor Service Tip > Page 4626 When using Cable "E" (Figure 3) to diagnose the DTR sensor, the slide switch must be in the "Digital" position and the "Black" 12-pin connector installed on the sensor. Having the slide switch in the incorrect position or using the incorrect 12-pin connector will result in misdiagnosis and possible replacement of a good component. For diagnosis of the DTR sensor, always refer to the appropriate model 1997 Service Manual, Section 07.01 or appropriate model 1997 Workshop Manual, Section 3O7-01 for proper procedure and required equipment. OTHER APPLICABLE ARTICLES: 95-19-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 503000, 503300, 504000, 601300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 4627 Transmission Position Switch/Sensor: Specifications TORQUE SPECIFICATIONS DTR Sensor Bolts ................................................................................................................................ ..................................... 7-10 Nm (62-89 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 4628 Transmission Position Switch/Sensor: Locations Transmission View The Digital Transmission Range Sensor is located at left side of the automatic transmission. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 4629 Digital Transmission Range Sensor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 4630 Transmission Position Switch/Sensor: Adjustments NOTE: Use Digital Transmission Range (DTR) Sensor Alignment Tool to align both TR and DTR sensors. 1. Raise and support vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Disconnect the manual lever shift control cable. 3. Disconnect the TR or DTR electrical connector. 4. Remove the manual control lever. (1) Remove the nut. (2) Remove the lever. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. 5. Loosen the TR or DTR bolts. 6. Use DTR sensor alignment tool, to align the DTR or TR sensor slots. NOTE: Manual shift lever must be in the neutral position. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 4631 7. Tighten the DTR or TR sensor bolts. 8. Install the manual control lever. (1) Position the manual control lever. (2) Install a new manual lever shaft outer nut. 9. With the manual lever in overdrive connect the shift lever control cable. 10. Install the DTR sensor electrical connector. 11. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications TORQUE SPECIFICATIONS Vehicle Speed Sensor (VSS) Bolt ........................................................................................................................................ 11-13 Nm (98-115 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 4635 Vehicle Speed Sensor: Locations Transmission View The Vehicle Speed Sensor is located at left rear of transmission. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4638 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4639 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4640 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4641 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4642 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4643 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4644 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 4645 Vehicle Speed Sensor: Description and Operation Purpose The Vehicle Speed (VSS) Sensor: - Is gear driven by the transmission. - Sends a signal to the PCM indicating transmission speed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 4646 Vehicle Speed Sensor: Service and Repair REMOVAL 1. Disconnect the battery. 2. Raise and support the vehicle. WARNING: The electrical power to the air suspension system must be shut OFF prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning OFF the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during 1 these operations. 3. Remove the Vehicle Speed Sensor (VSS). (1) Disconnect the electrical connector. (2) Remove the bolt. (3) Remove the VSS. 4. Remove the Vehicle Speed Sensor (VSS) drive gear. INSTALLATION 1. Install the Vehicle Speed Sensor (VSS) drive gear. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 4647 2. Install the VSS. (1) Install the VSS. (2) Install the bolt. (3) Connect the electrical connector. 3. Remove supports and lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning ON the air suspension switch. 4. Reconnect the battery ground cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > Customer Interest for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise Catalyst Shield: Customer Interest Exhaust System - Buzzing/Rattling Noise Article No. 98-20-10 10/12/98 ^ EXHAUST SYSTEM - LOOSE CATALYST OR MUFFLER HEAT SHIELDS ^ NOISE - "BUZZING" OR "RATTLING" - LOOSE CATALYST OR MUFFLER HEAT SHIELDS FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-99 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-99 CONTOUR LINCOLN-MERCURY: 1993-94 CAPRI, TOPAZ 1993-99 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 F SUPER DUTY, F-35O 1993-99 AEROSTAR, ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER, VILLAGER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES This TSB article is being republished in its entirety to include additional vehicles and to include 1999 model year vehicles. ISSUE A "buzzing" or "rattling" noise from the exhaust system may be caused by a loose heat shield attachment to the catalytic converter, catalytic pipes, muffler pipes and/or muffler. The noise is noticeable during normal driving conditions or at engine idle. ACTION Install worm clamps to secure loose heat shield attachments. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect for loose shields. If shield(s) is missing, this TSB does not apply. Refer to the appropriate Service or Workshop Manual for repair procedures NOTE UNDER NO CIRCUMSTANCES SHOULD A HEAT SHIELD BE REMOVED WITHOUT REPLACEMENT BEFORE THE VEHICLE IS RETURNED TO THE CUSTOMER. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > Customer Interest for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 4658 2. Install worm clamps to the catalytic converter, catalytic pipes, muffler pipes or muffler as shown in Figure 1 for the typical light truck and Figure 2 for the typical passenger car. 3. Align the clamps to secure the heat shield to the catalytic converter, catalytic pipes, muffler pipes or muffler as required. 4. Tighten the clamps to 6.8 N.m (60 lb-in). 5. Trim the excess "ear" of the clamp to approximately 2.54 cm (1"). PART NUMBER PART NAME FOTZ-5A231-A Worm clamp (4-1/2" To 9-1/2") W705949-S300 Worm clamp (3/4" To 4") OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-6-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models Bumper To Bumper Warranty Coverage For 1992-99 Models, And Any Applicable Emissions Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > Customer Interest for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 4659 OPERATION DESCRIPTION TIME 982010A Install One (1), Two (2), Or 0.3 Hr. Four (4) Worm Clamps DEALER CODING CONDITION BASIC PART NO. CODE 5E258 33 OASIS CODES: 403000, 702000, 702100, 702200, 703000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise Catalyst Shield: All Technical Service Bulletins Exhaust System - Buzzing/Rattling Noise Article No. 98-20-10 10/12/98 ^ EXHAUST SYSTEM - LOOSE CATALYST OR MUFFLER HEAT SHIELDS ^ NOISE - "BUZZING" OR "RATTLING" - LOOSE CATALYST OR MUFFLER HEAT SHIELDS FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-99 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-99 CONTOUR LINCOLN-MERCURY: 1993-94 CAPRI, TOPAZ 1993-99 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 F SUPER DUTY, F-35O 1993-99 AEROSTAR, ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER, VILLAGER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES This TSB article is being republished in its entirety to include additional vehicles and to include 1999 model year vehicles. ISSUE A "buzzing" or "rattling" noise from the exhaust system may be caused by a loose heat shield attachment to the catalytic converter, catalytic pipes, muffler pipes and/or muffler. The noise is noticeable during normal driving conditions or at engine idle. ACTION Install worm clamps to secure loose heat shield attachments. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect for loose shields. If shield(s) is missing, this TSB does not apply. Refer to the appropriate Service or Workshop Manual for repair procedures NOTE UNDER NO CIRCUMSTANCES SHOULD A HEAT SHIELD BE REMOVED WITHOUT REPLACEMENT BEFORE THE VEHICLE IS RETURNED TO THE CUSTOMER. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 4665 2. Install worm clamps to the catalytic converter, catalytic pipes, muffler pipes or muffler as shown in Figure 1 for the typical light truck and Figure 2 for the typical passenger car. 3. Align the clamps to secure the heat shield to the catalytic converter, catalytic pipes, muffler pipes or muffler as required. 4. Tighten the clamps to 6.8 N.m (60 lb-in). 5. Trim the excess "ear" of the clamp to approximately 2.54 cm (1"). PART NUMBER PART NAME FOTZ-5A231-A Worm clamp (4-1/2" To 9-1/2") W705949-S300 Worm clamp (3/4" To 4") OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-6-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models Bumper To Bumper Warranty Coverage For 1992-99 Models, And Any Applicable Emissions Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 4666 OPERATION DESCRIPTION TIME 982010A Install One (1), Two (2), Or 0.3 Hr. Four (4) Worm Clamps DEALER CODING CONDITION BASIC PART NO. CODE 5E258 33 OASIS CODES: 403000, 702000, 702100, 702200, 703000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > Page 4667 Catalyst Shield: Specifications Heat Shield Screws 13-17 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Specifications Canister Purge Control Valve: Specifications Vapor Management Valve Bolts 8-10 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Specifications > Page 4672 Canister Purge Control Valve: Locations Engine View The Vapor Management Valve (VMV) is located on the LH rear of the engine compartment, and mounted to the firewall. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Specifications > Page 4673 Canister Purge Control Valve: Description and Operation EVAP Canister Purge Valve PURPOSE The Vapor Management Valve (VMV) controls the flow of vapors (purging) from the fuel vapor storage canister to the intake manifold during various engine operating modes. OPERATION The PCM outputs a variable duty cycle signal (between 0 and 100%) to the VMV solenoid to either divert more vacuum to the valve part of the VMV and open it, or vent more vacuum to the atmosphere at the solenoid and close the VMV. The increase in vacuum acting on the VMV diaphragm overcomes the valve spring and begins to lift the VMV pintle oft its seat, causing fuel vapor flow into the intake manifold. FEATURES The VMV is designed to compensate for changes in the intake manifold that is applied to the solenoid part of the VMV, and it will maintain a constant vapor flow at any given duty cycle for manifold vacuums between 16-67 kPa (5-20 in-Hg). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Specifications > Page 4674 Canister Purge Control Valve: Service and Repair REMOVAL 1. Disconnect the fuel vapor management valve electrical connector and the evaporative emissions vacuum control hose. 2. Disconnect the two fuel vapor tubes. 1 Disconnect the evaporative emissions service port-to-fuel vapor management valve tube. 2 Disconnect the throttle body spacer-to-fuel vapor management valve tube. 3. Remove the two fuel vapor management valve two bolts and remove valve. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Specifications Canister Purge Solenoid: Specifications Vapor Management Valve Bolts 8-10 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Specifications > Page 4678 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Specifications > Page 4679 Canister Purge Solenoid: Description and Operation EVAP Canister Purge Valve PURPOSE The Vapor Management Valve (VMV) controls the flow of vapors (purging) from the fuel vapor storage canister to the intake manifold during various engine operating modes. OPERATION The PCM outputs a variable duty cycle signal (between 0 and 100%) to the VMV solenoid to either divert more vacuum to the valve part of the VMV and open it, or vent more vacuum to the atmosphere at the solenoid and close the VMV. The increase in vacuum acting on the VMV diaphragm overcomes the valve spring and begins to lift the VMV pintle oft its seat, causing fuel vapor flow into the intake manifold. FEATURES The VMV is designed to compensate for changes in the intake manifold that is applied to the solenoid part of the VMV, and it will maintain a constant vapor flow at any given duty cycle for manifold vacuums between 16-67 kPa (5-20 in-Hg). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Specifications > Page 4680 Canister Purge Solenoid: Service and Repair REMOVAL 1. Disconnect the fuel vapor management valve electrical connector and the evaporative emissions vacuum control hose. 2. Disconnect the two fuel vapor tubes. 1 Disconnect the evaporative emissions service port-to-fuel vapor management valve tube. 2 Disconnect the throttle body spacer-to-fuel vapor management valve tube. 3. Remove the two fuel vapor management valve two bolts and remove valve. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Locations Evaporative Check Valve: Locations The Evaporative Emissions Valve is mounted in the top of the fuel tank and secured by a rubber grommet. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Locations > Page 4684 Evaporative Check Valve: Description and Operation Fuel Vapor Valve (Typical) Purpose Fuel vapors in the fuel tank are vented through the evaporative emission valve located in the top of the fuel tank. The vapors are transmitted through a single vapor tube to the evaporative emissions canister at the front of the vehicle. A spring loaded poppet valve provides relief ahead of the orifice to the evaporative emissions canister. Operation and Construction The evaporative emission valves makes use of a small orifice and shutoff valve that tends to allow only fuel vapor, not liquid, to pass into the fuel and vapor return tube routed forward to the evaporative emissions canister. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Locations > Page 4685 Evaporative Check Valve: Testing and Inspection Diagnosis, Testing, and Inspection procedures are addressed at the Powertrain Management Level. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications Evaporative Emission Control Canister: Specifications Canister Bolts 21-29 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications > Page 4689 Evaporative Emission Control Canister: Locations The Evaporative Emission Control Canister is located at the LR of the vehicle, and is mounted to the frame rail. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications > Page 4690 Evaporative Emission Control Canister: Description and Operation PURPOSE The fuel vapors from the fuel tank are stored in the fuel vapor storage canister. OPERATION When the vehicle is operating above idle, the vapors are purged from the fuel vapor storage canister into the engine for combustion. OBD II vehicle fuel vapor storage canisters are sometimes used in pairs depending on the size or number of fuel tanks. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications > Page 4691 Evaporative Emission Control Canister: Service and Repair REMOVAL WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This may be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air spring which may result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Disconnect the evaporative emissions canister purge solenoid electrical connector. 3. Loosen the clamp and remove the fuel vapor tube. 4. Remove the two evaporative emissions canister nuts and remove canister and bracket assembly. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications > Page 4692 To install, reverse the removal procedure. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Sensor, Evaporative System > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Sensor, Evaporative System > Component Information > Diagrams > Page 4696 Leak Detection Sensor: Description and Operation Fuel Tank Pressure (FTP) Sensor FUEL TANK PRESSURE SENSOR The Fuel Tank Pressure (FTP) sensor (A) is used to monitor the fuel tank pressure or vacuum during the OBD II purge monitor test of the Evaporative Emission System for Running Loss vehicles (passenger cars with fuel vapor control valves and trucks with fuel vapor valves). This monitor also performs a fuel system integrity check to determine if there is an evaporative emission system leak. Variations in pressure will be converted into an analog voltage input signal to the PCM. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid Vapor Separator, Evaporative System > Component Information > Locations Liquid Vapor Separator: Locations The Evaporative Emissions Valve is mounted in the top of the fuel tank and secured by a rubber grommet. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Backpressure Transducer > Component Information > Specifications EGR Backpressure Transducer: Specifications Backpressure Transducer Nuts 8-12 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Backpressure Transducer > Component Information > Specifications > Page 4704 EGR Backpressure Transducer: Description and Operation The EGR backpressure transducer: - Monitors the EGR flow rate through the EGR valve to exhaust manifold tube. - Sends an EGR flow rate signal to the PCM. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Backpressure Transducer > Component Information > Specifications > Page 4705 EGR Backpressure Transducer: Service and Repair REMOVAL 1. Remove the EGR backpressure transducer. 1 Remove the two EGR backpressure transducer tubes. 2 Disconnect the EGR backpressure transducer electrical connector. 3 Remove the two nuts. 4 Remove the EGR backpressure transducer. INSTALLATION To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Specifications EGR Electronic Vacuum Regulator Solenoid: Specifications Bracket Bolts 8-12 Nm Bracket Bolts and Nuts 8-12 Nm Solenoid Nuts 2.5-5.5 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Specifications > Page 4709 EGR Electronic Vacuum Regulator Solenoid: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Specifications > Page 4710 The EGR vacuum regulator solenoid is mounted to the intake plenum, below the Throttle Body. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Specifications > Page 4711 EGR Electronic Vacuum Regulator Solenoid: Description and Operation The EGR vacuum regulator solenoid uses input from the PCM to change the EGR valve operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Specifications > Page 4712 EGR Electronic Vacuum Regulator Solenoid: Service and Repair REMOVAL 1. Remove the EGR vacuum regulator solenoid. 1 Remove the vacuum connector. 2 Disconnect the electrical connector. 3 Remove the two nuts. 4 Remove the EGR vacuum regulator solenoid. INSTALLATION 1. Install the EGR vacuum regulator solenoid. 1 Position the EGR vacuum regulator solenoid. 2 Install the two nuts. 3 Connect the electrical connector. 4 Connect the vacuum connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications EGR Tube: Specifications EGR Valve to Exhaust Manifold Tube Fittings 34-47 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications > Page 4716 EGR Tube: Description and Operation The EGR valve to exhaust manifold tube: - Connects the exhaust manifold to the EGR valve. - Has two tubes connecting to the EGR backpressure transducer for EGR flow monitoring. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications > Page 4717 EGR Tube: Service and Repair REMOVAL 1. Remove the EGR valve to exhaust manifold tube. 1 Remove the two EGR backpressure transducer tubes. 2 Remove the EGR valve to exhaust manifold tube upper fitting. 3 Remove the (A) EGR valve to exhaust manifold lower tube fitting and the (B) EGR valve to exhaust manifold tube. INSTALLATION To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications EGR Valve: Specifications EGR Valve Bolts 8-11.5 Nm EGR Valve to Manifold Tube Fitting 34-47 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 4721 EGR Valve: Locations The EGR valve is mounted to the intake plenum, below the Throttle Body. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 4722 EGR Valve: Description and Operation Exhaust Gas Recirculation Valve Purpose The EGR valve increases or decreases the flow of exhaust gas recirculation. Description The EGR valve in the Differential Pressure Feedback EGR system is a conventional vacuum actuated EGR valve, and serves only as a pressure regulator rather than a flow metering device. Operation As vacuum applied to the EGR valve diaphragm overcomes the spring force, the valve begins to open. As the vacuum signal weakens, the spring force closes the valve. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 4723 EGR Valve: Service and Repair REMOVAL 1. Disconnect the EGR valve vacuum hose. 2. Remove the (A) brake booster tube bracket nut and the (B) brake booster tube bracket. 3. Disconnect the EGR valve to exhaust manifold tube upper fitting. 4. Remove the EGR valve. 1 Remove the two bolts. 2 Remove the EGR valve and the EGR valve gasket. Discard the gasket. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 4724 To install, reverse the removal procedure. Refer to corresponding illustration. NOTE: Install a new EGR valve gasket. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision Pressure Feedback Exhaust Sensor: Technical Service Bulletins EGR DPFE Sensor - Voltage Range Revision Article No. 97-22-1 10/27/97 DELTA PRESSURE FEEDBACK EGR (DPFE) - DIAGNOSTIC TIPS FORD: 1994-97 MUSTANG, THUNDERBIRD 1995-97 CONTOUR, CROWN VICTORIA 1996-97 ESCORT, TAURUS LINCOLN-MERCURY: 1990-97 TOWN CAR 1994-97 COUGAR 1995-97 CONTINENTAL, GRAND MARQUIS, MYSTIQUE 1996-97 SABLE, TRACER LIGHT TRUCK: 1994-97 EXPLORER 1995-97 ECONOLINE, F-150-350 SERIES, WINDSTAR 1996-97 AEROSTAR 1997 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: The current DPFE sensor diagnostic reference values as published in the Powertrain Control/Emissions Diagnosis (PC/ED) Service Manual, and also accessed by either the Service Bay Diagnostic System (SBDS) or Service Bay Technical System (SBTS), can lead to the replacement of good DPFE sensors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision > Page 4729 ACTION: Use the following revised DPFE sensor voltage ranges for all (black plastic or aluminum) DPFE system applications when checking the PID (Parameter Identifier Display) value "DPFEGR" or when measuring the DPFE sensor input directly at the breakout box. Refer to Figure 1. NOTE: THESE LISTED VOLTAGE RANGES SHOULD BE USED FOR ALL (BLACK PLASTIC OR ALUMINUM) DPFE SYSTEM APPLICATIONS WHENEVER CHECKING THE PID VALUE "DPFEGR" OR WHEN MEASURING THE DPFE SENSOR INPUT DIRECTLY AT THE BREAKOUT BOX. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4730 Pressure Feedback Exhaust Sensor: Locations Engine View The Differential Pressure Feedback EGR (DPFE) Sensor is located at the right side of engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Technical Service Bulletins > Customer Interest for PCV Valve Hose: > 98-21-10 > Oct > 98 > Engine - High Idle Speeds/Throttle Sticks PCV Valve Hose: Customer Interest Engine - High Idle Speeds/Throttle Sticks Article No. 98-21-10 10/26/98 IDLE - HIGH IDLE SPEEDS - THROTTLE STICKS AFTER STEADY STATE DRIVING IN COLD AMBIENT TEMPERATURES - VEHICLES BUILT THROUGH 12/1/97 EQUIPPED WITH 4.6L ENGINE LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD ISSUE The vehicles identified in this TSB article should be equipped with an insulated PCV tube that was installed in production or under Recall 96S59. This insulation provides protection from PCV backflow due to ice in the PCV system created during steady speed driving in extremely cold weather. In those extreme cases where the insulated PCV tube does not completely eliminate throttle body icing due to PCV backflow, a service kit has been developed that will make these vehicles even less susceptible to PCV freezing. ACTION Verify that the condition is not caused by throttle body sludging, throttle cable binding, or interference between an improperly positioned floor mat and accelerator pedal. If no other conditions are identified, replace the PCV hose and throttle body adapter provided with the appropriate service kit. Refer to the Instruction Sheet included in the kit for installation details. PART NUMBER PART NAME F85Z-6A603-CB Service Kit - 4.6L Romeo Engine F85Z-6A603-AB Service Kit - 4.6L Windsor Engine OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 982110A Install Service kit 1.1 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 9E926 42 OASIS CODES: 404000, 610000, 610600, 612000, 612600, 617400, 619400 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PCV Valve Hose: > 98-21-10 > Oct > 98 > Engine - High Idle Speeds/Throttle Sticks PCV Valve Hose: All Technical Service Bulletins Engine - High Idle Speeds/Throttle Sticks Article No. 98-21-10 10/26/98 IDLE - HIGH IDLE SPEEDS - THROTTLE STICKS AFTER STEADY STATE DRIVING IN COLD AMBIENT TEMPERATURES - VEHICLES BUILT THROUGH 12/1/97 EQUIPPED WITH 4.6L ENGINE LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD ISSUE The vehicles identified in this TSB article should be equipped with an insulated PCV tube that was installed in production or under Recall 96S59. This insulation provides protection from PCV backflow due to ice in the PCV system created during steady speed driving in extremely cold weather. In those extreme cases where the insulated PCV tube does not completely eliminate throttle body icing due to PCV backflow, a service kit has been developed that will make these vehicles even less susceptible to PCV freezing. ACTION Verify that the condition is not caused by throttle body sludging, throttle cable binding, or interference between an improperly positioned floor mat and accelerator pedal. If no other conditions are identified, replace the PCV hose and throttle body adapter provided with the appropriate service kit. Refer to the Instruction Sheet included in the kit for installation details. PART NUMBER PART NAME F85Z-6A603-CB Service Kit - 4.6L Romeo Engine F85Z-6A603-AB Service Kit - 4.6L Windsor Engine OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 982110A Install Service kit 1.1 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 9E926 42 OASIS CODES: 404000, 610000, 610600, 612000, 612600, 617400, 619400 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Technical Service Bulletins > Page 4745 PCV Valve Hose: Locations The PCV hoses are attached to the: - PCV valve in the LH valve cover. - Crankcase breather in the RH valve cover Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations Positive Crankcase Ventilation Valve: Locations The PCV valve is located in the valve cover and secured by a rubber grommet. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Leak Detection Sensor, Evaporative System > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Leak Detection Sensor, Evaporative System > Component Information > Diagrams > Page 4753 Leak Detection Sensor: Description and Operation Fuel Tank Pressure (FTP) Sensor FUEL TANK PRESSURE SENSOR The Fuel Tank Pressure (FTP) sensor (A) is used to monitor the fuel tank pressure or vacuum during the OBD II purge monitor test of the Evaporative Emission System for Running Loss vehicles (passenger cars with fuel vapor control valves and trucks with fuel vapor valves). This monitor also performs a fuel system integrity check to determine if there is an evaporative emission system leak. Variations in pressure will be converted into an analog voltage input signal to the PCM. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision Pressure Feedback Exhaust Sensor: Technical Service Bulletins EGR DPFE Sensor - Voltage Range Revision Article No. 97-22-1 10/27/97 DELTA PRESSURE FEEDBACK EGR (DPFE) - DIAGNOSTIC TIPS FORD: 1994-97 MUSTANG, THUNDERBIRD 1995-97 CONTOUR, CROWN VICTORIA 1996-97 ESCORT, TAURUS LINCOLN-MERCURY: 1990-97 TOWN CAR 1994-97 COUGAR 1995-97 CONTINENTAL, GRAND MARQUIS, MYSTIQUE 1996-97 SABLE, TRACER LIGHT TRUCK: 1994-97 EXPLORER 1995-97 ECONOLINE, F-150-350 SERIES, WINDSTAR 1996-97 AEROSTAR 1997 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: The current DPFE sensor diagnostic reference values as published in the Powertrain Control/Emissions Diagnosis (PC/ED) Service Manual, and also accessed by either the Service Bay Diagnostic System (SBDS) or Service Bay Technical System (SBTS), can lead to the replacement of good DPFE sensors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision > Page 4758 ACTION: Use the following revised DPFE sensor voltage ranges for all (black plastic or aluminum) DPFE system applications when checking the PID (Parameter Identifier Display) value "DPFEGR" or when measuring the DPFE sensor input directly at the breakout box. Refer to Figure 1. NOTE: THESE LISTED VOLTAGE RANGES SHOULD BE USED FOR ALL (BLACK PLASTIC OR ALUMINUM) DPFE SYSTEM APPLICATIONS WHENEVER CHECKING THE PID VALUE "DPFEGR" OR WHEN MEASURING THE DPFE SENSOR INPUT DIRECTLY AT THE BREAKOUT BOX. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4759 Pressure Feedback Exhaust Sensor: Locations Engine View The Differential Pressure Feedback EGR (DPFE) Sensor is located at the right side of engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications Fuel Pressure Test Port: Specifications Pressure Relief Valve 7.75 Nm Pressure Relief Valve Cap 0.6 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 4765 Fuel Pressure Test Port: Locations Typical Location The fuel pressure test point/port is a Schrader fitting, located in the fuel rail. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 4766 Fuel Pressure Test Port: Service Precautions WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited, resulting in possible injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. - Before repairing or disconnecting any of the fuel lines or fuel system components, the fuel system fuel pressure release procedure must be performed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 4767 Fuel Pressure Test Port: Description and Operation Typical Location Purpose There is a pressure test point with a Schrader fitting in the fuel rail, which is used for fuel pressure release and to measure the injector supply pressure for service and diagnostic work. NOTE:Before servicing or testing the fuel system, read CAUTION, WARNING, and HANDLING information. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 4768 Fuel Pressure Test Port: Service and Repair REMOVAL 1. Perform Fuel Pressure Release Procedure 2. Remove the fuel pressure relief valve. INSTALLATION To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Locations Fuel Pressure Release: Locations Fuel Pressure Port (Typical) A fuel system service port is provided on the fuel rail. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Locations > Page 4772 Fuel Pressure Release: Service Precautions WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited, resulting in possible injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. - Before repairing or disconnecting any of the fuel lines or fuel system components, the fuel system fuel pressure release procedure must be performed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Locations > Page 4773 Fuel Pressure Release: Service and Repair Fuel Pressure Port (Typical) 1. Remove the schrader valve cap and attach EFI/CFI Fuel Pressure Gauge. 2. Open the manual valve on EFI/CFI Fuel Pressure Gauge and Perform Fuel Pressure Release. NOTE: Open manual value slowly to relieve system pressure. - This will drain some fuel out of the system. - Place fuel in suitable a container. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Idle Speed (Non-Adjustable) Idle Speed (Non-Adjustable) Base Idle Speed (Standard Trans/Hot) 750 +/- 25 rpm Base Idle Speed (Automatic Trans/Hot) 824 +/- 25 rpm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > Page 4777 Idle Speed: Adjustments Engine Idle RPM is controlled by the PCM and is NOT adjustable. If a problem exists, or is suspected, see: Powertrain Management / Symptom Charts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > System Diagnosis Air/Fuel Mixture: Testing and Inspection To avoid potential misdiagnosis and the unnecessary replacement of components, it is recommended that diagnosis and testing begin with Diagnostic Routines (Diagnosis by Symptom) at the Powertrain Management level. The Diagnostic Routines will lead the technician through the logical and methodical testing of a "specific" subsystem and it's related wiring and components. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > System Diagnosis > Page 4781 Air/Fuel Mixture: Adjustments Air Fuel Ratio is NOT adjustable. If a problem exists, or is suspected, go to the Diagnostic Charts: See Powertrain Management Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications Accelerator Pedal: Specifications Pedal and Shaft Bolts 23.3-31.7 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service Precautions > Customer Safety Information Accelerator Pedal: Customer Safety Information WARNING: - No surrounding engine compartment components such as wiring or hoses may contact any moving member of the accelerator controls. All vehicles are to be checked for return to idle as follows: no perceptible hesitation or prevention of return to idle may occur during slow removal of the foot from the accelerator pedal and shaft, starting at the fully depressed wide open throttle position. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service Precautions > Customer Safety Information > Page 4787 Accelerator Pedal: Vehicle Damage Warnings WARNING: - No surrounding engine compartment components such as wiring or hoses may contact any moving member of the accelerator controls. All vehicles are to be checked for return to idle as follows: no perceptible hesitation or prevention of return to idle may occur during slow removal of the foot from the accelerator pedal and shaft, starting at the fully depressed wide open throttle position. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service Precautions > Page 4788 Accelerator Pedal: Description and Operation The throttle opening is controlled by: - accelerator cable. - accelerator pedal and shaft. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service Precautions > Page 4789 Accelerator Pedal: Testing and Inspection INSPECTION AND VERIFICATION NOTE: Care should be exercised when performing service on or around the accelerator pedal linkage and controls: - Inspect the accelerator pedal and shaft and attaching linkage for damage or distortion which would bind or limit accelerator travel. - Inspect the accelerator cable for kinks or fraying which may cause binding. - Inspect the engine idle speed adjustment to ensure correct idle speed specification after any accelerator linkage adjustment or repair. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service Precautions > Page 4790 Accelerator Pedal: Service and Repair REMOVAL 1. Disconnect the (A) accelerator cable from the (B) accelerator pedal and shaft. 2. Remove the accelerator pedal and shaft bolts. 3. Remove the accelerator pedal and shaft. INSTALLATION To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Tube Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Outlet Tube REMOVAL 1. Remove the accelerator control splash shield. 1 Remove the accelerator control splash shield bolts. 2 Remove the accelerator control splash shield. 2. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 3. Disconnect the (A) positive crankcase ventilation hose and the (B) idle air control valve inlet tube. 4. Loosen the two air cleaner outlet tube hose clamp screws and remove the air cleaner outlet tube. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Tube > Page 4796 To install, reverse the removal procedure. CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Tube > Page 4797 Air Cleaner Fresh Air Duct/Hose: Service and Repair Removal and Installation REMOVAL 1. Open the (A) air cleaner clamp and set the (B) outlet engine air cleaner aside. 2. Lift the (B) open end of the (A) inlet engine air cleaner until free of the (C) engine air cleaner support insulators. CAUTION: The inlet engine air cleaner should be removed as an assembly. Do not separate the air cleaner from the fender inlet tube during removal or installation. 3. Pull the inlet engine air cleaner away from the inner fender. INSTALLATION CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. NOTE: The inlet engine air cleaner has an alignment tab which fits into a slot on the outlet engine air cleaner. This ensures a good seal and keeps unmetered air from entering the engine. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL 1. Open the (A) air cleaner clamp and set the (B) outlet engine air cleaner aside. 2. Remove the (A) air cleaner element from the (B) open end of the inlet engine air cleaner. INSTALLATION 1. Install the air cleaner element. NOTE: The inlet engine air cleaner has an alignment tab which fits into a slot on the outlet engine air cleaner. This ensures a good seal and keeps unmetered air from entering the engine. CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. 2. Position the engine air cleaner aligning the alignment tab. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 4801 3. Close the air cleaner clamp. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4810 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4811 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4817 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4818 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement Air Flow Meter/Sensor: All Technical Service Bulletins Mass Air Flow Sensor - Assembly Replacement Article No. 96-22-5 10/21/96 MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP FORD: 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR, EXPLORER, RANGER 1993-97 VILLAGER 1994-96 BRONCO 1994-97 ECONOLINE 1995-97 F-150, WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: The Mass Air Flow (MAF) sensor is not designed to be removed from its body (die-cast or plastic) for servicing. The sensing elements located inside the by-pass tube can be damaged by poking/probing/touching. ACTION: Service the MAF sensor as an assembly (refer to Figure 1). WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement > Page 4823 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement Air Flow Meter/Sensor: All Technical Service Bulletins Mass Air Flow Sensor - Assembly Replacement Article No. 96-22-5 10/21/96 MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP FORD: 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR, EXPLORER, RANGER 1993-97 VILLAGER 1994-96 BRONCO 1994-97 ECONOLINE 1995-97 F-150, WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: The Mass Air Flow (MAF) sensor is not designed to be removed from its body (die-cast or plastic) for servicing. The sensing elements located inside the by-pass tube can be damaged by poking/probing/touching. ACTION: Service the MAF sensor as an assembly (refer to Figure 1). WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement > Page 4829 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 4830 Air Flow Meter/Sensor: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 4831 RH Component The Mass Air Flow Sensor is located in air cleaner assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 4832 Air Flow Meter/Sensor: Description and Operation PURPOSE The Mass Air Flow (MAF) sensor: - Sends the PCM a signal indicating mass airflow rate of air entering the engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal Air Flow Meter/Sensor: Service and Repair Removal REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Open the engine air cleaner. - Disconnect the Mass Air Flow (MAF) sensor connector from the wiring harness. - Release the air cleaner clamp. Separate the inlet side of the air cleaner from the outlet side of the air cleaner. 3. Cut the tape on the wire loom of the extension harness. CAUTION: Do not cut the MAF sensor wires when cutting the tape on the wire loom. - Peel back the wire loom from the extension harness near the grommet in the air cleaner. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal > Page 4835 4. Remove the grommet from the outlet side of the air cleaner and slide the grommet down the extension harness. 5. Remove the MAF sensor plate and MAF sensor from the outlet side of the engine air cleaner. 6. Disconnect the MAF sensor electrical connector. 7. Remove the nuts and separate the MAF plate from the MAF sensor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal > Page 4836 Air Flow Meter/Sensor: Service and Repair Installation INSTALLATION CAUTION: - Do not tamper with the MAF sensing elements located in the airflow bypass; tampering may result in unit failure. - The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. NOTE: - Use the alignment notch to properly align the inlet side and the outlet side of the engine air cleaner. - The MAF sensor module and body are calibrated and replaced as a unit. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set Auxiliary Air Valve (Idle Speed): Customer Interest Engine - Fast Idle Speed/MIL ON/DTC P1506 Set Article No. 98-21-21 10/26/98 ^ IDLE - FAST IDLE SPEED AND/OR DIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY - VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE ^ MALFUNCTION INDICATOR LAMP (MIL) - MIL ILLUMINATED AND/OR FAST IDLE SPEED WITH 31GDIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY - VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED AND/OR FAST IDLE SPEED WITH DIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY-VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE LIGHT TRUCK: 1997-98 ECONOLINE, EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 4845 This TSB article is being republished in its entirety to add service parts, include a Part Application Chart, and to revise Figure 1. ISSUE The Malfunction Indicator Lamp (MIL) may illuminate and Diagnostic Trouble Code (DTC) P1506 may be stored in continuous memory and/or the engine idle speed may be higher than expected. This may be caused by black plastic flash from idle air bypass hose becoming lodged in the Idle Air Control (IAC) bypass valve. ACTION Refer to the Diagnostic Flow Chart (Figure 1) for diagnostic and servicing procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 4846 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-13-17 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 982121A Perform TSB Diagnostics 0.8 Hr. (Includes Replace Idle Air Control Resonator And Inspect Or Replace Idle Air Control Valve) Vehicles Built Before 4/15/98 982121B Perform TSB Diagnostics 0.5 Hr. (Includes Replace Idle Air Control Valve) - Vehicles Built After 4/15/98 DEALER CODING CONDITION BASIC PART NO. CODE 9H308 42 OASIS CODES: 206000, 608000, 608400, 619400, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set Auxiliary Air Valve (Idle Speed): All Technical Service Bulletins Engine - Fast Idle Speed/MIL ON/DTC P1506 Set Article No. 98-21-21 10/26/98 ^ IDLE - FAST IDLE SPEED AND/OR DIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY - VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE ^ MALFUNCTION INDICATOR LAMP (MIL) - MIL ILLUMINATED AND/OR FAST IDLE SPEED WITH 31GDIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY - VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED AND/OR FAST IDLE SPEED WITH DIAGNOSTIC TROUBLE CODE (DTC) P1506 STORED IN MEMORY-VEHICLES BUILT WITH 4.6L, 5.4L, OR 6.8L ENGINE LIGHT TRUCK: 1997-98 ECONOLINE, EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 4852 This TSB article is being republished in its entirety to add service parts, include a Part Application Chart, and to revise Figure 1. ISSUE The Malfunction Indicator Lamp (MIL) may illuminate and Diagnostic Trouble Code (DTC) P1506 may be stored in continuous memory and/or the engine idle speed may be higher than expected. This may be caused by black plastic flash from idle air bypass hose becoming lodged in the Idle Air Control (IAC) bypass valve. ACTION Refer to the Diagnostic Flow Chart (Figure 1) for diagnostic and servicing procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 98-21-21 > Oct > 98 > Engine - Fast Idle Speed/MIL ON/DTC P1506 Set > Page 4853 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-13-17 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 982121A Perform TSB Diagnostics 0.8 Hr. (Includes Replace Idle Air Control Resonator And Inspect Or Replace Idle Air Control Valve) Vehicles Built Before 4/15/98 982121B Perform TSB Diagnostics 0.5 Hr. (Includes Replace Idle Air Control Valve) - Vehicles Built After 4/15/98 DEALER CODING CONDITION BASIC PART NO. CODE 9H308 42 OASIS CODES: 206000, 608000, 608400, 619400, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel - Volatility Related Driveability Concerns Fuel: Technical Service Bulletins Fuel - Volatility Related Driveability Concerns Article No. 98-26-2 01/04/99 FUEL - INFORMATION ON GASOLINE - TIPS TO RESOLVE VOLATILITY RELATED DRIVEABILITY CONCERNS FORD: 1985-97 THUNDERBIRD 1986-99 MUSTANG, TAURUS 1987-99 ESCORT 1988-94 TEMPO 1989-97 PROBE 1990-99 CROWN VICTORIA 1992-93 FESTIVA 1995-99 CONTOUR LINCOLN-MERCURY: 1985-97 COUGAR 1986-92 MARK VII 1986-99 SABLE 1987-89 TRACER 1988-94 TOPAZ 1988-99 CONTINENTAL 1990-99 GRAND MARQUIS, TOWN CAR 1991-99 TRACER 1993-98 MARK VIII 1995-99 MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1986-97 AEROSTAR 1987-96 BRONCO 1989-97 F SUPER DUTY, F-350 1989-99 F-150, F-250 LD, RANGER 1991-99 EXPLORER 1992-99 ECONOLINE 1993-99 VILLAGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1990-97 F-700 This TSB article is being republished in its entirety to expand vehicle model coverage and revise the text. ISSUE Some vehicles using winter blend fuels may exhibit a stall on start up and a no restart, hard start condition or a no start condition in unseasonably hot weather (greater than 27°C/80°F). These concerns may be related to fuel volatility from winter blend fuels during winter-spring and autumn-winter transitions and may result in a fuel pump vapor lock condition. This condition may appear to be a fuel pump failure but may be caused by winter blend fuel. ACTION Refer to the following text for further information. NOTE FUEL TANK ADDITIVES WILL NOT RESOLVE THESE CONCERNS BECAUSE VAPOR FORMS FROM CAVITATION WITHIN THE FUEL PUMP. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel - Volatility Related Driveability Concerns > Page 4858 FILLING THE TANK TO FULL MAY BE EFFECTIVE. ADVISE CUSTOMER TO USE THE RECOMMENDED OCTANE GRADE PER OWNER MANUAL AND NOT A HIGHER GRADE. Explain to the customer that this concern may be due to a low tank level of winter blend fuel combined with unseasonably warm weather. Advise customer that filling the fuel tank to full may be effective in resolving this concern. Also, advise customer to use the recommended octane grade per their Owner Manual and not a higher grade. BACKGROUND Gasolines are seasonally adjusted, meaning they have higher volatility (vaporize easier) in the winter and lower volatility in the summer. Government mandates to improve air quality have resulted in significant changes to gasolines, such as the mandatory use of oxygenates (ethanol, methyl tertiary butyl ether (MTBE), and others) in the winter or the reduction of Reid Vapor Pressure (RVP) in the summer. The addition of oxygenates (especially ethanol) increases volatility while the reduction of RVP reduces volatility. Gasoline distribution practices often do not allow branded marketers to have much control over their gasoline's volatility other than RVP. Oxygenate (e.g., ethanol, MTBE) use is more dependent on local gasoline markets, rather than specific marketers practice. Therefore, it is difficult to recommend specific brands to avoid volatility related complaints. OTHER APPLICABLE ARTICLES: 91-8-13 SUPERSEDES: 96-5-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES:402000, 404000, 602300, 603300, 607000, 607400, 608000, 608400, 609000, 609400, 610000, 611000, 611500, 612000, 614000, 614500, 623000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Page 4859 Fuel: Specifications Octane Requirement Octane Requirement Minimum Octane Rating 87 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Page 4860 Fuel: Testing and Inspection PREPARATION Obtain a fuel sample from the bottom of the fuel tank so that any water present will be detected. The sample should be bright and clear. If the sample appears cloudy or contaminated with water (indicated by a layer at the bottom of the sample), this procedure should not be used and fuel system should be cleaned. TESTING 1. Fill a 100 ml cylinder with 1 ml graduation marks to the 90 ml mark. 2. Add 10 ml of water to bring the total fluid volume to 100 ml. Install a stopper. 3. Shake vigorously for 10 to 15 seconds. 4. Loosen stopper to release pressure. 5. Close stopper and repeat shaking for 10 to 15 seconds. 6. Place the cylinder on a level surface for approximately 5 minutes to allow adequate liquid separation. RESULTS EVALUATION If alcohol is present, the volume of the lower layer (now containing both alcohol and water) will be greater than 10 ml. For example, if lower layer volume is increased to 15 ml, it indicates at least 5 percent alcohol in the fuel. The actual amount of alcohol may be somewhat greater because this procedure does not extract all alcohol from fuel. Allowable Alcohol/Fuel Concentration Alcohol/Fuel Type % by Volume Methanol (Wood Alcohol) 5.0% Ethanol (Grain Alcohol) 10.0% MTBE (Methyl Tertiary Butyl Ether) 15.0% Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Cap: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4869 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4870 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4871 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4872 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4873 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Cap: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4879 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4880 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4881 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4882 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4883 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 962618 > Dec > 96 > New Locking Fuel Caps - Available Fuel Filler Cap: All Technical Service Bulletins New Locking Fuel Caps - Available Article No. 96-26-18 12/16/96 ^ FUEL - LOCKING GASOLINE CAPS - NEW PART AVAILABILITY ^ LOCKING FUEL CAPS - NEW PART AVAILABILITY LIGHT TRUCK: 1997 EXPEDITION, F-150, F-250 ISSUE: New locking gasoline caps are now available from Ford Motor Company. The caps have not been previously offered for these vehicles. ACTION: If a locking gasoline cap is requested on the subject vehicles, refer to the following Application Chart for correct part usage APPLICATION CHART Vehicle Part Number 1997 F-150 with threaded cap F75Z-9030-FA 1997 F-150/250 and Expedition F75Z-9030-GA with 1/8th turn cap PART NUMBER PART NAME F75Z-9030-FA Gasoline cap F75Z-9030-GA Gasoline cap OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000, 404000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Filler Cap: > 962618 > Dec > 96 > New Locking Fuel Caps - Available Fuel Filler Cap: All Technical Service Bulletins New Locking Fuel Caps - Available Article No. 96-26-18 12/16/96 ^ FUEL - LOCKING GASOLINE CAPS - NEW PART AVAILABILITY ^ LOCKING FUEL CAPS - NEW PART AVAILABILITY LIGHT TRUCK: 1997 EXPEDITION, F-150, F-250 ISSUE: New locking gasoline caps are now available from Ford Motor Company. The caps have not been previously offered for these vehicles. ACTION: If a locking gasoline cap is requested on the subject vehicles, refer to the following Application Chart for correct part usage APPLICATION CHART Vehicle Part Number 1997 F-150 with threaded cap F75Z-9030-FA 1997 F-150/250 and Expedition F75Z-9030-GA with 1/8th turn cap PART NUMBER PART NAME F75Z-9030-FA Gasoline cap F75Z-9030-GA Gasoline cap OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000, 404000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Locations Fuel Pressure Release: Locations Fuel Pressure Port (Typical) A fuel system service port is provided on the fuel rail. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Locations > Page 4897 Fuel Pressure Release: Service Precautions WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited, resulting in possible injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. - Before repairing or disconnecting any of the fuel lines or fuel system components, the fuel system fuel pressure release procedure must be performed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Locations > Page 4898 Fuel Pressure Release: Service and Repair Fuel Pressure Port (Typical) 1. Remove the schrader valve cap and attach EFI/CFI Fuel Pressure Gauge. 2. Open the manual valve on EFI/CFI Fuel Pressure Gauge and Perform Fuel Pressure Release. NOTE: Open manual value slowly to relieve system pressure. - This will drain some fuel out of the system. - Place fuel in suitable a container. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Description and Operation Fuel Injector Wiring Harness: Description and Operation PURPOSE The fuel injection wiring harness provides an electrical path from the PCM to the fuel injectors, electronic engine controls, and sensors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service and Repair > Removal Fuel Injector Wiring Harness: Service and Repair Removal WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. Fuel in the fuel system remains under high pressure even when the engine is not running. - The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. 1. Disconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Remove the wiring splash shield. 3. Disconnect the engine bulkhead connector. 4. Disconnect the (A) fuel charging wiring electrical connector from the (B) engine control sensor wiring electrical connector. NOTE: The (A) fuel charging wiring electrical connector and the (B) engine control sensor wiring electrical connectors are located behind the (C) mount. 5. Disconnect the Engine Vacuum Regulator (EVR) electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service and Repair > Removal > Page 4905 6. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. Generator removed for clarity 7. Disconnect the Intake Manifold Tuning Valve (IMTV) electrical connector. 8. Disconnect the following electrical connections: - LH ignition coil connector (A). - Camshaft Position (CMP) sensor electrical connector (B). - Radio capacitor electrical connector (C). 9. Disconnect the following electrical connectors. - RH ignition coil electrical connector (A). - Radio capacitor electrical connector (B). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service and Repair > Removal > Page 4906 10. Remove the accelerator control splash shield. 1 Remove the three accelerator control splash shield bolts. 2 Remove the accelerator control splash shield. 11. Disconnect the following electrical connectors: - Idle Air Control (IAC) valve electrical connector (A). - Differential Pressure Feedback EGR (DPFE) transducer electrical connector (B). - Engine Vacuum Regulator (EVR) electrical connector (C). - Throttle Position (TP) sensor electrical connector (D). 12. Disconnect the engine cooling system sensor connections. - Disconnect the (A) Engine Coolant Temperature (ECT) sensor electrical connector. - Disconnect the (B) water temperature indicator sender unit electrical connector. 13. Disconnect the four RH fuel injector electrical connectors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service and Repair > Removal > Page 4907 14. Disconnect the four LH fuel injector electrical connectors. 15. Raise and support the vehicle. 16. Disconnect the A/C compressor clutch electrical connector. NOTE: The A/C compressor clutch electrical connector can be reached through the wheel well. Transmission removed for clarity 17. Disconnect the two Heated Oxygen Sensor (HO2S) electrical connectors. 18. Disconnect the Crankshaft Position (CKP) sensor electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service and Repair > Removal > Page 4908 19. Disconnect the oil pressure sending unit electrical connector. 20. Lower the vehicle. 21. Remove the fuel charging wiring. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service and Repair > Removal > Page 4909 Fuel Injector Wiring Harness: Service and Repair Installation WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. 1. Position the fuel charging wiring on the engine. 2. Raise and support the vehicle. 3. Connect the oil pressure sending unit electrical connector. 4. Connect the Crankshaft Position (CKP) sensor electrical connector. Transmission removed for clarity 5. Connect the two Heated Oxygen Sensor (H02S) electrical connectors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service and Repair > Removal > Page 4910 6. Connect the A/C compressor clutch electrical connector. 7. Lower the vehicle. 8. Connect the LH fuel injector electrical connectors. 9. Connect the RH fuel injector electrical connectors. 10. Connect the engine cooling system sensor connections. - Connect the (A) Engine Coolant Temperature (ECT) sensor electrical connector. - Connect the (B) water temperature indicator sender unit electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service and Repair > Removal > Page 4911 11. Connect the following electrical connectors: - Idle Air Control (IAC) valve electrical/connector (A). - Differential Pressure Feedback EGR (DPFE) transducer electrical connector (B). - Engine Vacuum Regulator (EVR) electrical connector (C). - Throttle Position (TP) sensor electrical connector (D). 12. Connect the following electrical connections: - LH ignition coil connector (A). - Camshaft Position Sensor (CMP) electrical connector (B). - Radio capacitor electrical connector (C). 13. Connect the following electrical connectors. - RH ignition coil electrical connector (A). - Radio capacitor electrical connector (B). Generator removed for clarity Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service and Repair > Removal > Page 4912 14. Connect the Intake Manifold Tuning Valve (IMTV) electrical connector. 15. Connect the Intake Air Temperature (IAT) sensor electrical connector. 16. Connect the fuel charging wiring electrical connector to the engine control sensor wiring electrical connector. 17. Connect the engine bulkhead connector. 18. Install the wiring splash shield. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service and Repair > Removal > Page 4913 19. Install the accelerator control splash shield. 20. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Technical Service Bulletins > Customer Interest: > 98-16-12 > Aug > 98 > Fuel Rail - Fuel Leaks At Spring Lock Coupler Fuel Line Coupler: Customer Interest Fuel Rail - Fuel Leaks At Spring Lock Coupler Article No. 98-16-12 08/17/98 FUEL SYSTEM - FUEL LEAKING FROM SPRING LOCK COUPLINGS AT FUEL RAIL - AMBIENT TEMPERATURES BELOW -40 DEGREES CELSIUS (-40 DEGREES FAHRENHEIT) LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR ISSUE Fuel may leak from the spring lock couplings at the fuel rail if the 0-rings have been damaged or at ambient temperatures below -40°C (-4O°F). This may be caused by the spring lock coupling 0-rings not sealing. ACTION Service replacement 0-rings are now available. Replace the spring lock coupling 0-rings. Refer to the following Service Procedure for details. SERVICE PROCEDURE Refer to the 1998 F-150/250 or Expedition/Navigator Workshop Manual, Pages 310-00-8 through 310-00-10 to disconnect the spring lock connectors and remove the 0-rings. Refer to the following to install the new 0-rings and reconnect the spring lock connectors: 1. Inspect and clean both coupling ends. 2. It female cup damage is observed such as interior scratches, replace the fuel rail. It no damage is observed to either the male or female coupling ends, replace the 0-rings being sure to observe the color coding as in Figure 1. 3. Lubricate the 0-rings with clean engine oil meeting Ford specification WSS-M2C153-F. 4. Connect the fitting. 5. Pull on the fitting to make sure it is fully engaged. 6. Install the safety clip. 7. Start the engine and check for fuel leaks. PART NUMBER PART NAME Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Technical Service Bulletins > Customer Interest: > 98-16-12 > Aug > 98 > Fuel Rail - Fuel Leaks At Spring Lock Coupler > Page 4922 F75Z-9J277-AA 0-Ring - Supply Side (Black, 1/2") F75Z-9J277-BA 0-Ring - Supply Side (Blue, 1/2") F75Z-9J277-DA 0-Ring - Return Side (Black, 3/8") F75Z-9J277-CA 0-Ring - Return Side (Blue, 3/8") OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 981612A Replace Spring Lock 0.6 Hr. Coupling 0-Rings DEALER CODING CONDITION BASIC PART NO. CODE 9J274 42 OASIS CODES: 404000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-16-12 > Aug > 98 > Fuel Rail - Fuel Leaks At Spring Lock Coupler Fuel Line Coupler: All Technical Service Bulletins Fuel Rail - Fuel Leaks At Spring Lock Coupler Article No. 98-16-12 08/17/98 FUEL SYSTEM - FUEL LEAKING FROM SPRING LOCK COUPLINGS AT FUEL RAIL - AMBIENT TEMPERATURES BELOW -40 DEGREES CELSIUS (-40 DEGREES FAHRENHEIT) LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR ISSUE Fuel may leak from the spring lock couplings at the fuel rail if the 0-rings have been damaged or at ambient temperatures below -40°C (-4O°F). This may be caused by the spring lock coupling 0-rings not sealing. ACTION Service replacement 0-rings are now available. Replace the spring lock coupling 0-rings. Refer to the following Service Procedure for details. SERVICE PROCEDURE Refer to the 1998 F-150/250 or Expedition/Navigator Workshop Manual, Pages 310-00-8 through 310-00-10 to disconnect the spring lock connectors and remove the 0-rings. Refer to the following to install the new 0-rings and reconnect the spring lock connectors: 1. Inspect and clean both coupling ends. 2. It female cup damage is observed such as interior scratches, replace the fuel rail. It no damage is observed to either the male or female coupling ends, replace the 0-rings being sure to observe the color coding as in Figure 1. 3. Lubricate the 0-rings with clean engine oil meeting Ford specification WSS-M2C153-F. 4. Connect the fitting. 5. Pull on the fitting to make sure it is fully engaged. 6. Install the safety clip. 7. Start the engine and check for fuel leaks. PART NUMBER PART NAME Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-16-12 > Aug > 98 > Fuel Rail - Fuel Leaks At Spring Lock Coupler > Page 4928 F75Z-9J277-AA 0-Ring - Supply Side (Black, 1/2") F75Z-9J277-BA 0-Ring - Supply Side (Blue, 1/2") F75Z-9J277-DA 0-Ring - Return Side (Black, 3/8") F75Z-9J277-CA 0-Ring - Return Side (Blue, 3/8") OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 981612A Replace Spring Lock 0.6 Hr. Coupling 0-Rings DEALER CODING CONDITION BASIC PART NO. CODE 9J274 42 OASIS CODES: 404000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Line Coupler: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Neck: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Line Coupler: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4934 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Line Coupler: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4935 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Line Coupler: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4936 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Line Coupler: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4937 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Line Coupler: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4938 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Line Coupler: > 97-11-17 > May > 97 > Fuel System - Slow Fuel Filling/Early Nozzle Shut-Off Fuel Filler Neck: All Technical Service Bulletins Fuel System - Slow Fuel Filling/Early Nozzle Shut-Off Article No. 97-11-17 05/27/97 FUEL - SLOW FILL OR INABILITY TO PUMP GASOLINE INTO FILL NECK AT SERVICE STATIONS LIGHT TRUCK: 1997 EXPEDITION ISSUE: A slow fill or the inability to fill the fuel tank may be experienced on some vehicles. This may be a result of fuel pumps that have a flow rate that is too high, or nozzles that are not within SAE design standards. ACTION: Customer may back off the nozzle 12 mm (0.5") and fill normally. If not satisfied, the customer may have the fuel filler pipe replaced on vehicles built prior to March 26, 1997. The new fill pipe entry makes the design more tolerant of nozzles which do not follow the SAE standard. However, if a customer is using a nozzle that is not close to the SAE standard, then the customer may continue to have problems with early fuel shutoff, even with the new fuel fill pipe. Refer to the following Service Procedure for details. SERVICE PROCEDURE REMOVAL 1. Remove the Fuel Tank Filler Cap (-9030-). 2. Remove the fuel tank filler pipe screws. 3. Remove the filler pipe-to-floor panel screws. 4. Loosen the hose clamp and disconnect the fuel filler vent hose from the fuel tank filler pipe. 5. Disconnect and remove the fuel tank filler pipe. INSTALLATION 1. Connect the new Fuel Tank Filler Pipe (F75Z-9034-BF) and tighten the hose clamp to 3.9-6.3 N.m (34.5-56 lb-in). 2. Reconnect the fuel filler vent hose to the fuel tank filler pipe and tighten the hose clamp to 3.9-6.3 N.m (34.5-56 lb-in). 3. Install and tighten the filler pipe-to-floor panel screws to 7.6-10.4 N.m (67-92 lb-in). 4. Install and tighten the fuel tank filler pipe screws to 1.6-2.2 N.m (14-19.5 lb-in). 5. Replace the Fuel Tank Filler Cap (-9030-). PART NUMBER PART NAME F75Z-9034-BF Fuel Tank Filler Pipe OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971117A Replace Fuel Tank Filler 0.3 Hr. Pipe DEALER CODING CONDITION BASIC PART NO. CODE 9034 16 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Line Coupler: > 97-11-17 > May > 97 > Fuel System - Slow Fuel Filling/Early Nozzle Shut-Off > Page 4943 OASIS CODES: 404000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Line Coupler: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4949 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Line Coupler: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4950 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Line Coupler: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4951 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Line Coupler: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4952 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Line Coupler: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4953 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Line Coupler: > 97-11-17 > May > 97 > Fuel System - Slow Fuel Filling/Early Nozzle Shut-Off > Page 4958 OASIS CODES: 404000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Technical Service Bulletins > Page 4959 Fuel Line Coupler: Service Precautions WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited, resulting in possible injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. - Before repairing or disconnecting any of the fuel lines or fuel system components, the fuel system fuel pressure release procedure must be performed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation > Push Connect Fittings Fuel Line Coupler: Description and Operation Push Connect Fittings Push connect fitting: - Has a safety retainer. - Is sealed by two O-rings. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation > Push Connect Fittings > Page 4962 Fuel Line Coupler: Description and Operation Spring Lock Coupling The spring lock coupling: - Has a bead formed in one tube. - Has a garter spring inside a cage on the other tube. - Is sealed by an O-ring on cage side. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Coupling Fuel Line Coupler: Service and Repair Spring Lock Coupling DISCONNECT 1. Perform Fuel Pressure Release. 2. Remove fuel tube clip. 3. Install Disconnect Tool (3/8 inch or 1/2 inch). 4. Close and push Disconnect Tool into the open side of the cage. 5. Separate the fitting. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Coupling > Page 4965 6. Remove Disconnect Tool. CONNECT To install, reverse the removal procedure. NOTE: Inspect and clean both coupling ends. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Coupling > Page 4966 Fuel Line Coupler: Service and Repair Push Connect Fittings WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. - Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved. DISCONNECT 1. Perform Fuel Pressure Release. 2. Disconnect the safety clip from the male hose. 3. Install and push the (A) fuel line disconnect tool into the (B) female fitting. 4. Separate the male and female fittings. - Inspect for damage. CONNECT Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Coupling > Page 4967 1. Align and push the (A) tube into the (B) fitting until a click is heard. 2. Pull on the fitting to make sure it is fully engaged, then install safety clip. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Check Valve > Component Information > Description and Operation Fuel Pressure Check Valve: Description and Operation Description The fuel pump assembly has a discharge check valve that maintains system pressure after the ignition has been turned off. The Fuel Pressure check valve is integral to the fuel pump assembly, and is NOT serviceable. Purpose This pressure retention helps to minimize starting problems. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications Fuel Pressure Regulator: Specifications Pressure Regulator Screws 3.0-4.5 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications > Page 4974 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications > Page 4975 Fuel Pressure Regulator: Service Precautions WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited, resulting in possible injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. - Before repairing or disconnecting any of the fuel lines or fuel system components, the fuel system fuel pressure release procedure must be performed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications > Page 4976 Fuel Pressure Regulator: Description and Operation Fuel Pressure Regulator Purpose To regulate the fuel pressure supplied to the fuel injectors. Operation The fuel pressure regulator is a diaphragm-operated relief valve in which one side of the diaphragm senses fuel pressure and the other side is subjected to intake manifold vacuum. The nominal fuel pressure is established by a spring preload applied to the diaphragm. Balancing one side of the diaphragm with manifold pressure maintains a constant fuel pressure drop across the fuel injectors. Fuel in excess of that used by the engine is bypassed through the fuel pressure regulator and returns to the fuel tank. Locations The fuel pressure regulator is attached to the fuel injection supply manifold downstream of the fuel injectors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications > Page 4977 Fuel Pressure Regulator: Service and Repair REMOVAL 1. Perform Fuel Pressure Release Procedure. 2. Remove the fuel pressure regulator. 1 Disconnect the fuel pressure regulator vacuum hose. 2 Remove the two fuel pressure regulator screws. 3 Remove the fuel pressure regulator. 3. Remove and discard the two (A) fuel pressure regulator O-rings and the (B) seal. INSTALLATION CAUTION: Use O-rings that are made of special fuel resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse O-rings. NOTE: Lubricate the new seal and O-rings with engine oil. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Specifications Fuel Pressure Test Port: Specifications Pressure Relief Valve 7.75 Nm Pressure Relief Valve Cap 0.6 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Specifications > Page 4981 Fuel Pressure Test Port: Locations Typical Location The fuel pressure test point/port is a Schrader fitting, located in the fuel rail. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Specifications > Page 4982 Fuel Pressure Test Port: Service Precautions WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited, resulting in possible injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. - Before repairing or disconnecting any of the fuel lines or fuel system components, the fuel system fuel pressure release procedure must be performed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Specifications > Page 4983 Fuel Pressure Test Port: Description and Operation Typical Location Purpose There is a pressure test point with a Schrader fitting in the fuel rail, which is used for fuel pressure release and to measure the injector supply pressure for service and diagnostic work. NOTE:Before servicing or testing the fuel system, read CAUTION, WARNING, and HANDLING information. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Specifications > Page 4984 Fuel Pressure Test Port: Service and Repair REMOVAL 1. Perform Fuel Pressure Release Procedure 2. Remove the fuel pressure relief valve. INSTALLATION To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications Fuel Pressure Test Port: Specifications Pressure Relief Valve 7.75 Nm Pressure Relief Valve Cap 0.6 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 4990 Fuel Pressure Test Port: Locations Typical Location The fuel pressure test point/port is a Schrader fitting, located in the fuel rail. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 4991 Fuel Pressure Test Port: Service Precautions WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited, resulting in possible injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. - Before repairing or disconnecting any of the fuel lines or fuel system components, the fuel system fuel pressure release procedure must be performed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 4992 Fuel Pressure Test Port: Description and Operation Typical Location Purpose There is a pressure test point with a Schrader fitting in the fuel rail, which is used for fuel pressure release and to measure the injector supply pressure for service and diagnostic work. NOTE:Before servicing or testing the fuel system, read CAUTION, WARNING, and HANDLING information. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 4993 Fuel Pressure Test Port: Service and Repair REMOVAL 1. Perform Fuel Pressure Release Procedure 2. Remove the fuel pressure relief valve. INSTALLATION To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 4997 Power Distribution Box The Fuel Pump Relay is located in the LH front of engine compartment, in the Power Distribution box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Description and Operation Fuel Pump Pickup Filter: Description and Operation Fuel Pump Module A nylon filter element: - is mounted on the electric fuel pump inlet inside the fuel tank. - is used to protect the fuel pump from fuel tank contaminants. - is NOT available separately. To service the in-tank filter, replace the fuel pump and sender assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Description and Operation > Page 5001 Fuel Pump Pickup Filter: Service and Repair The nylon filter element is NOT available separately. To service the in-tank filter, replace the fuel pump and sender assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Customer Interest: > 98-16-12 > Aug > 98 > Fuel Rail - Fuel Leaks At Spring Lock Coupler Fuel Rail: Customer Interest Fuel Rail - Fuel Leaks At Spring Lock Coupler Article No. 98-16-12 08/17/98 FUEL SYSTEM - FUEL LEAKING FROM SPRING LOCK COUPLINGS AT FUEL RAIL - AMBIENT TEMPERATURES BELOW -40 DEGREES CELSIUS (-40 DEGREES FAHRENHEIT) LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR ISSUE Fuel may leak from the spring lock couplings at the fuel rail if the 0-rings have been damaged or at ambient temperatures below -40°C (-4O°F). This may be caused by the spring lock coupling 0-rings not sealing. ACTION Service replacement 0-rings are now available. Replace the spring lock coupling 0-rings. Refer to the following Service Procedure for details. SERVICE PROCEDURE Refer to the 1998 F-150/250 or Expedition/Navigator Workshop Manual, Pages 310-00-8 through 310-00-10 to disconnect the spring lock connectors and remove the 0-rings. Refer to the following to install the new 0-rings and reconnect the spring lock connectors: 1. Inspect and clean both coupling ends. 2. It female cup damage is observed such as interior scratches, replace the fuel rail. It no damage is observed to either the male or female coupling ends, replace the 0-rings being sure to observe the color coding as in Figure 1. 3. Lubricate the 0-rings with clean engine oil meeting Ford specification WSS-M2C153-F. 4. Connect the fitting. 5. Pull on the fitting to make sure it is fully engaged. 6. Install the safety clip. 7. Start the engine and check for fuel leaks. PART NUMBER PART NAME Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Customer Interest: > 98-16-12 > Aug > 98 > Fuel Rail - Fuel Leaks At Spring Lock Coupler > Page 5010 F75Z-9J277-AA 0-Ring - Supply Side (Black, 1/2") F75Z-9J277-BA 0-Ring - Supply Side (Blue, 1/2") F75Z-9J277-DA 0-Ring - Return Side (Black, 3/8") F75Z-9J277-CA 0-Ring - Return Side (Blue, 3/8") OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 981612A Replace Spring Lock 0.6 Hr. Coupling 0-Rings DEALER CODING CONDITION BASIC PART NO. CODE 9J274 42 OASIS CODES: 404000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-16-12 > Aug > 98 > Fuel Rail - Fuel Leaks At Spring Lock Coupler Fuel Rail: All Technical Service Bulletins Fuel Rail - Fuel Leaks At Spring Lock Coupler Article No. 98-16-12 08/17/98 FUEL SYSTEM - FUEL LEAKING FROM SPRING LOCK COUPLINGS AT FUEL RAIL - AMBIENT TEMPERATURES BELOW -40 DEGREES CELSIUS (-40 DEGREES FAHRENHEIT) LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR ISSUE Fuel may leak from the spring lock couplings at the fuel rail if the 0-rings have been damaged or at ambient temperatures below -40°C (-4O°F). This may be caused by the spring lock coupling 0-rings not sealing. ACTION Service replacement 0-rings are now available. Replace the spring lock coupling 0-rings. Refer to the following Service Procedure for details. SERVICE PROCEDURE Refer to the 1998 F-150/250 or Expedition/Navigator Workshop Manual, Pages 310-00-8 through 310-00-10 to disconnect the spring lock connectors and remove the 0-rings. Refer to the following to install the new 0-rings and reconnect the spring lock connectors: 1. Inspect and clean both coupling ends. 2. It female cup damage is observed such as interior scratches, replace the fuel rail. It no damage is observed to either the male or female coupling ends, replace the 0-rings being sure to observe the color coding as in Figure 1. 3. Lubricate the 0-rings with clean engine oil meeting Ford specification WSS-M2C153-F. 4. Connect the fitting. 5. Pull on the fitting to make sure it is fully engaged. 6. Install the safety clip. 7. Start the engine and check for fuel leaks. PART NUMBER PART NAME Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-16-12 > Aug > 98 > Fuel Rail - Fuel Leaks At Spring Lock Coupler > Page 5016 F75Z-9J277-AA 0-Ring - Supply Side (Black, 1/2") F75Z-9J277-BA 0-Ring - Supply Side (Blue, 1/2") F75Z-9J277-DA 0-Ring - Return Side (Black, 3/8") F75Z-9J277-CA 0-Ring - Return Side (Blue, 3/8") OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 981612A Replace Spring Lock 0.6 Hr. Coupling 0-Rings DEALER CODING CONDITION BASIC PART NO. CODE 9J274 42 OASIS CODES: 404000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Rail: > 98-20-10 > Oct > 98 > Exhaust System Buzzing/Rattling Noise Heat Shield: All Technical Service Bulletins Exhaust System - Buzzing/Rattling Noise Article No. 98-20-10 10/12/98 ^ EXHAUST SYSTEM - LOOSE CATALYST OR MUFFLER HEAT SHIELDS ^ NOISE - "BUZZING" OR "RATTLING" - LOOSE CATALYST OR MUFFLER HEAT SHIELDS FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-99 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-99 CONTOUR LINCOLN-MERCURY: 1993-94 CAPRI, TOPAZ 1993-99 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 F SUPER DUTY, F-35O 1993-99 AEROSTAR, ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER, VILLAGER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES This TSB article is being republished in its entirety to include additional vehicles and to include 1999 model year vehicles. ISSUE A "buzzing" or "rattling" noise from the exhaust system may be caused by a loose heat shield attachment to the catalytic converter, catalytic pipes, muffler pipes and/or muffler. The noise is noticeable during normal driving conditions or at engine idle. ACTION Install worm clamps to secure loose heat shield attachments. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect for loose shields. If shield(s) is missing, this TSB does not apply. Refer to the appropriate Service or Workshop Manual for repair procedures NOTE UNDER NO CIRCUMSTANCES SHOULD A HEAT SHIELD BE REMOVED WITHOUT REPLACEMENT BEFORE THE VEHICLE IS RETURNED TO THE CUSTOMER. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Rail: > 98-20-10 > Oct > 98 > Exhaust System Buzzing/Rattling Noise > Page 5022 2. Install worm clamps to the catalytic converter, catalytic pipes, muffler pipes or muffler as shown in Figure 1 for the typical light truck and Figure 2 for the typical passenger car. 3. Align the clamps to secure the heat shield to the catalytic converter, catalytic pipes, muffler pipes or muffler as required. 4. Tighten the clamps to 6.8 N.m (60 lb-in). 5. Trim the excess "ear" of the clamp to approximately 2.54 cm (1"). PART NUMBER PART NAME FOTZ-5A231-A Worm clamp (4-1/2" To 9-1/2") W705949-S300 Worm clamp (3/4" To 4") OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-6-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models Bumper To Bumper Warranty Coverage For 1992-99 Models, And Any Applicable Emissions Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Rail: > 98-20-10 > Oct > 98 > Exhaust System Buzzing/Rattling Noise > Page 5023 OPERATION DESCRIPTION TIME 982010A Install One (1), Two (2), Or 0.3 Hr. Four (4) Worm Clamps DEALER CODING CONDITION BASIC PART NO. CODE 5E258 33 OASIS CODES: 403000, 702000, 702100, 702200, 703000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Rail: > 98-20-10 > Oct > 98 > Exhaust System Buzzing/Rattling Noise > Page 5029 2. Install worm clamps to the catalytic converter, catalytic pipes, muffler pipes or muffler as shown in Figure 1 for the typical light truck and Figure 2 for the typical passenger car. 3. Align the clamps to secure the heat shield to the catalytic converter, catalytic pipes, muffler pipes or muffler as required. 4. Tighten the clamps to 6.8 N.m (60 lb-in). 5. Trim the excess "ear" of the clamp to approximately 2.54 cm (1"). PART NUMBER PART NAME FOTZ-5A231-A Worm clamp (4-1/2" To 9-1/2") W705949-S300 Worm clamp (3/4" To 4") OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-6-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models Bumper To Bumper Warranty Coverage For 1992-99 Models, And Any Applicable Emissions Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Rail: > 98-20-10 > Oct > 98 > Exhaust System Buzzing/Rattling Noise > Page 5030 OPERATION DESCRIPTION TIME 982010A Install One (1), Two (2), Or 0.3 Hr. Four (4) Worm Clamps DEALER CODING CONDITION BASIC PART NO. CODE 5E258 33 OASIS CODES: 403000, 702000, 702100, 702200, 703000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 5031 Fuel Rail: Specifications Injection Supply Manifold Bolts 8-11 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 5032 Fuel Rail: Locations The fuel injection supply manifold (fuel rail) is located alongside the lower intake manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 5033 Fuel Rail: Service Precautions WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited, resulting in possible injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. - The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Removal Fuel Rail: Service and Repair Removal REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Perform Fuel Pressure Release Procedure. 3. Partially drain the cooling system. 4. Remove the power steering reservoir bracket. 1 Remove the three power steering reservoir bolts. 2 Position the power steering reservoir bracket out of the way. 5. Remove the accelerator control splash shield. 1 Remove the three accelerator control splash shield bolts. 2 Remove the accelerator control splash shield. 6. Disconnect the fuel pressure regulator valve vacuum hose. 7. Disconnect the two fuel lines. CAUTION: After disconnecting, plug the fuel lines to prevent leakage. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Removal > Page 5036 8. Disconnect the four RH fuel injector electrical connectors. 9. Disconnect the four LH fuel injector electrical connectors. 10. Disconnect the heater water inlet tube hose. 1 Release and move the hose clamp. 2 Disconnect the heater water inlet tube hose and position aside. 11. Remove the brake booster tube bracket. 1 Remove the brake booster tube bracket nut. 2 Release and move the two hose clamps. 3 Remove the brake booster tube. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Removal > Page 5037 12. Remove the Positive Crankcase Ventilation (PCV) hose. 13. Disconnect the EGR connections. - Two DPFE transducer hoses (B). - EGR valve to exhaust manifold tube upper fitting (A). - EGR valve to exhaust manifold tube lower fitting and remove the EGR exhaust tube (C). 14. Disconnect the EGR valve vacuum hose. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Removal > Page 5038 15. Disconnect the Vapor Management Valve (VMV) hose. 16. Remove the four fuel injection supply manifold bolts and lift the fuel injection supply manifold and injectors upward, out of the intake manifold. 17. Remove the fuel injectors from the fuel injection supply manifold. 18. Remove and discard the two O-rings from each fuel injector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Removal > Page 5039 19. Remove the fuel injection supply manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Removal > Page 5040 Fuel Rail: Service and Repair Installation INSTALLATION 1. Install two O-rings to each fuel injector. NOTE: Lubricate new O-rings with engine oil. - If O-rings need to be replaced, use service replacement O-rings. 2. Install the fuel injectors into the intake manifold. 3. Install the fuel injection supply manifold to the fuel injectors. 4. Install the fuel injection supply manifold bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Removal > Page 5041 5. Connect the Vapor Management Valve (VMV) hose. 6. Connect the Exhaust Gas Recirculation (EGR) valve vacuum hose. 7. Connect the EGR connections: - Two DPFE transducer hoses (A). - EGR valve to exhaust manifold tube upper fitting (B). - EGR valve to exhaust manifold tube lower fitting (C). 8. Install the PCV hose. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Removal > Page 5042 9. Install the brake booster tube bracket. 1 Install the brake booster tube. 2 Install the two hose clamps. 3 Install the brake booster tube bracket nut. 10. Connect the heater water inlet tube. 1 Connect the heater inlet tube hose to inlet tube. 2 Slide the clamp into position. 11. Connect the four LH fuel injector electrical connectors. 12. Connect the four RH fuel injector electrical connectors. 13. Connect the two fuel lines Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Removal > Page 5043 14. Connect the fuel pressure regulator valve vacuum hose. 15. Install the accelerator splash shield. 16. Install the power steering reservoir bracket. 17. Fill the cooling system. 18. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Page 5044 Fuel Rail: Tools and Equipment Spring Lock Coupling Disconnect Tool (3/8 inch) or equivalent D87 - L-9280-A Spring Lock Coupling Disconnect Tool (1/2 inch) or equivalent D87 - L-9280-B Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Hose: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5054 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5055 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5056 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5057 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5058 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 97-11-17 > May > 97 > Fuel System - Slow Fuel Filling/Early Nozzle Shut-Off Fuel Filler Hose: Customer Interest Fuel System - Slow Fuel Filling/Early Nozzle Shut-Off Article No. 97-11-17 05/27/97 FUEL - SLOW FILL OR INABILITY TO PUMP GASOLINE INTO FILL NECK AT SERVICE STATIONS LIGHT TRUCK: 1997 EXPEDITION ISSUE: A slow fill or the inability to fill the fuel tank may be experienced on some vehicles. This may be a result of fuel pumps that have a flow rate that is too high, or nozzles that are not within SAE design standards. ACTION: Customer may back off the nozzle 12 mm (0.5") and fill normally. If not satisfied, the customer may have the fuel filler pipe replaced on vehicles built prior to March 26, 1997. The new fill pipe entry makes the design more tolerant of nozzles which do not follow the SAE standard. However, if a customer is using a nozzle that is not close to the SAE standard, then the customer may continue to have problems with early fuel shutoff, even with the new fuel fill pipe. Refer to the following Service Procedure for details. SERVICE PROCEDURE REMOVAL 1. Remove the Fuel Tank Filler Cap (-9030-). 2. Remove the fuel tank filler pipe screws. 3. Remove the filler pipe-to-floor panel screws. 4. Loosen the hose clamp and disconnect the fuel filler vent hose from the fuel tank filler pipe. 5. Disconnect and remove the fuel tank filler pipe. INSTALLATION 1. Connect the new Fuel Tank Filler Pipe (F75Z-9034-BF) and tighten the hose clamp to 3.9-6.3 N.m (34.5-56 lb-in). 2. Reconnect the fuel filler vent hose to the fuel tank filler pipe and tighten the hose clamp to 3.9-6.3 N.m (34.5-56 lb-in). 3. Install and tighten the filler pipe-to-floor panel screws to 7.6-10.4 N.m (67-92 lb-in). 4. Install and tighten the fuel tank filler pipe screws to 1.6-2.2 N.m (14-19.5 lb-in). 5. Replace the Fuel Tank Filler Cap (-9030-). PART NUMBER PART NAME F75Z-9034-BF Fuel Tank Filler Pipe OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971117A Replace Fuel Tank Filler 0.3 Hr. Pipe DEALER CODING CONDITION BASIC PART NO. CODE 9034 16 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 97-11-17 > May > 97 > Fuel System - Slow Fuel Filling/Early Nozzle Shut-Off > Page 5063 OASIS CODES: 404000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Hose: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5069 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5070 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5071 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5072 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5073 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 97-11-17 > May > 97 > Fuel System - Slow Fuel Filling/Early Nozzle Shut-Off Fuel Filler Hose: All Technical Service Bulletins Fuel System - Slow Fuel Filling/Early Nozzle Shut-Off Article No. 97-11-17 05/27/97 FUEL - SLOW FILL OR INABILITY TO PUMP GASOLINE INTO FILL NECK AT SERVICE STATIONS LIGHT TRUCK: 1997 EXPEDITION ISSUE: A slow fill or the inability to fill the fuel tank may be experienced on some vehicles. This may be a result of fuel pumps that have a flow rate that is too high, or nozzles that are not within SAE design standards. ACTION: Customer may back off the nozzle 12 mm (0.5") and fill normally. If not satisfied, the customer may have the fuel filler pipe replaced on vehicles built prior to March 26, 1997. The new fill pipe entry makes the design more tolerant of nozzles which do not follow the SAE standard. However, if a customer is using a nozzle that is not close to the SAE standard, then the customer may continue to have problems with early fuel shutoff, even with the new fuel fill pipe. Refer to the following Service Procedure for details. SERVICE PROCEDURE REMOVAL 1. Remove the Fuel Tank Filler Cap (-9030-). 2. Remove the fuel tank filler pipe screws. 3. Remove the filler pipe-to-floor panel screws. 4. Loosen the hose clamp and disconnect the fuel filler vent hose from the fuel tank filler pipe. 5. Disconnect and remove the fuel tank filler pipe. INSTALLATION 1. Connect the new Fuel Tank Filler Pipe (F75Z-9034-BF) and tighten the hose clamp to 3.9-6.3 N.m (34.5-56 lb-in). 2. Reconnect the fuel filler vent hose to the fuel tank filler pipe and tighten the hose clamp to 3.9-6.3 N.m (34.5-56 lb-in). 3. Install and tighten the filler pipe-to-floor panel screws to 7.6-10.4 N.m (67-92 lb-in). 4. Install and tighten the fuel tank filler pipe screws to 1.6-2.2 N.m (14-19.5 lb-in). 5. Replace the Fuel Tank Filler Cap (-9030-). PART NUMBER PART NAME F75Z-9034-BF Fuel Tank Filler Pipe OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971117A Replace Fuel Tank Filler 0.3 Hr. Pipe DEALER CODING CONDITION BASIC PART NO. CODE 9034 16 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 97-11-17 > May > 97 > Fuel System - Slow Fuel Filling/Early Nozzle Shut-Off > Page 5078 OASIS CODES: 404000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 5079 Fuel Filler Hose: Specifications Filler Pipe Screws 1.6-2.2 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 5080 Fuel Filler Hose: Service and Repair REMOVAL 1. Remove fuel tank filler cap. 2. Remove the fuel tank filler pipe screws. 3. Loosen the hose clamp and disconnect the fuel filler vent hose from the fuel tank filler pipe. 4. Disconnect the fuel tank filler pipe hose and remove the fuel tank filler pipe. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 5081 To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Neck: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5090 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5091 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5092 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5093 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5094 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 97-11-17 > May > 97 > Fuel System - Slow Fuel Filling/Early Nozzle Shut-Off Fuel Filler Neck: Customer Interest Fuel System - Slow Fuel Filling/Early Nozzle Shut-Off Article No. 97-11-17 05/27/97 FUEL - SLOW FILL OR INABILITY TO PUMP GASOLINE INTO FILL NECK AT SERVICE STATIONS LIGHT TRUCK: 1997 EXPEDITION ISSUE: A slow fill or the inability to fill the fuel tank may be experienced on some vehicles. This may be a result of fuel pumps that have a flow rate that is too high, or nozzles that are not within SAE design standards. ACTION: Customer may back off the nozzle 12 mm (0.5") and fill normally. If not satisfied, the customer may have the fuel filler pipe replaced on vehicles built prior to March 26, 1997. The new fill pipe entry makes the design more tolerant of nozzles which do not follow the SAE standard. However, if a customer is using a nozzle that is not close to the SAE standard, then the customer may continue to have problems with early fuel shutoff, even with the new fuel fill pipe. Refer to the following Service Procedure for details. SERVICE PROCEDURE REMOVAL 1. Remove the Fuel Tank Filler Cap (-9030-). 2. Remove the fuel tank filler pipe screws. 3. Remove the filler pipe-to-floor panel screws. 4. Loosen the hose clamp and disconnect the fuel filler vent hose from the fuel tank filler pipe. 5. Disconnect and remove the fuel tank filler pipe. INSTALLATION 1. Connect the new Fuel Tank Filler Pipe (F75Z-9034-BF) and tighten the hose clamp to 3.9-6.3 N.m (34.5-56 lb-in). 2. Reconnect the fuel filler vent hose to the fuel tank filler pipe and tighten the hose clamp to 3.9-6.3 N.m (34.5-56 lb-in). 3. Install and tighten the filler pipe-to-floor panel screws to 7.6-10.4 N.m (67-92 lb-in). 4. Install and tighten the fuel tank filler pipe screws to 1.6-2.2 N.m (14-19.5 lb-in). 5. Replace the Fuel Tank Filler Cap (-9030-). PART NUMBER PART NAME F75Z-9034-BF Fuel Tank Filler Pipe OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971117A Replace Fuel Tank Filler 0.3 Hr. Pipe DEALER CODING CONDITION BASIC PART NO. CODE 9034 16 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 97-11-17 > May > 97 > Fuel System - Slow Fuel Filling/Early Nozzle Shut-Off > Page 5099 OASIS CODES: 404000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Neck: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5105 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5106 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5107 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5108 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5109 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 97-11-17 > May > 97 > Fuel System - Slow Fuel Filling/Early Nozzle Shut-Off Fuel Filler Neck: All Technical Service Bulletins Fuel System - Slow Fuel Filling/Early Nozzle Shut-Off Article No. 97-11-17 05/27/97 FUEL - SLOW FILL OR INABILITY TO PUMP GASOLINE INTO FILL NECK AT SERVICE STATIONS LIGHT TRUCK: 1997 EXPEDITION ISSUE: A slow fill or the inability to fill the fuel tank may be experienced on some vehicles. This may be a result of fuel pumps that have a flow rate that is too high, or nozzles that are not within SAE design standards. ACTION: Customer may back off the nozzle 12 mm (0.5") and fill normally. If not satisfied, the customer may have the fuel filler pipe replaced on vehicles built prior to March 26, 1997. The new fill pipe entry makes the design more tolerant of nozzles which do not follow the SAE standard. However, if a customer is using a nozzle that is not close to the SAE standard, then the customer may continue to have problems with early fuel shutoff, even with the new fuel fill pipe. Refer to the following Service Procedure for details. SERVICE PROCEDURE REMOVAL 1. Remove the Fuel Tank Filler Cap (-9030-). 2. Remove the fuel tank filler pipe screws. 3. Remove the filler pipe-to-floor panel screws. 4. Loosen the hose clamp and disconnect the fuel filler vent hose from the fuel tank filler pipe. 5. Disconnect and remove the fuel tank filler pipe. INSTALLATION 1. Connect the new Fuel Tank Filler Pipe (F75Z-9034-BF) and tighten the hose clamp to 3.9-6.3 N.m (34.5-56 lb-in). 2. Reconnect the fuel filler vent hose to the fuel tank filler pipe and tighten the hose clamp to 3.9-6.3 N.m (34.5-56 lb-in). 3. Install and tighten the filler pipe-to-floor panel screws to 7.6-10.4 N.m (67-92 lb-in). 4. Install and tighten the fuel tank filler pipe screws to 1.6-2.2 N.m (14-19.5 lb-in). 5. Replace the Fuel Tank Filler Cap (-9030-). PART NUMBER PART NAME F75Z-9034-BF Fuel Tank Filler Pipe OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971117A Replace Fuel Tank Filler 0.3 Hr. Pipe DEALER CODING CONDITION BASIC PART NO. CODE 9034 16 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 97-11-17 > May > 97 > Fuel System - Slow Fuel Filling/Early Nozzle Shut-Off > Page 5114 OASIS CODES: 404000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly Technical Service Bulletin # 97B17 Date: 980201 Campaign - Fuel Gauge/Sender Assembly 97517 OWNER NOTIFICATION PROGRAM Fuel Gauge/Sender Assembly Replacement Original - February, 1998 Dealer Letter Attachment I ^ Administrative Information ^ Refund Codes Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Supplement # 1 - April, 1998 Supplement # 2 - November, 1998 Revised Expiration Date For Owner Notification Program 98B17 - Fuel Gauge/sender Replacement ^ IMPORTANT INFORMATION OWNER NOTIFICATION PROGRAM 97B17 EXPIRATION DATE ^ Attachments not Applicable ^ Customer Notification Letter not Applicable Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5123 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Affected vehicles on the enclosed list. ^ Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5124 Enter claims using DWE. See ACESII Manual, Sections 5 and 6. OWNER REFUNDS See ACESII Manual, Section 3-63 for submission procedures. For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Program Code - 97B17 Misc. Expense - REFUND Misc. Expense - ADMIN. Misc. Expense - 0.2 Hr. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order fuel sender assemblies and the gaskets through normal processing channels. PART NUMBER/DESCRIPTION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5125 Fuel Sender Assembly - NOTE: Some of the following applications will require gaskets to be ordered in addition to the sender assemblies. DEALER PRICE For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. CLAIMS PREPARATION Enter using DWE. Use code information shown below: ^ Program Code - 97B17 ^ Labor Operation Code - See Above See Sections 5 and 6 of the ACESII Manual for detailed instructions Affected Vehicle and Warning Information AFFECTED VEHICLES: CERTAIN 1997 TAURUS/SABLE, EXPLORER/MOUNTAINEER, EXPEDITION, MUSTANG AND 1998 WINDSTAR WARNING DO NOT SWALLOW GASOLINE, THESE FUELS ARE HIGHLY TOXIC AND IF SWALLOWED CAN CAUSE DEATH OR PERMANENT INJURY, SWALLOWING METHANOL CAN ALSO CAUSE BLINDNESS. CALL A PHYSICIAN IMMEDIATELY TO TREAT ANYONE WHO HAS SWALLOWED FUEL METHANOL OR FUEL ETHANOL. VOMITING SHOULD BE INDUCED BY OR UNDER THE DIRECTION OF A PHYSICIAN OR POISON CONTROL CENTER. BE AWARE THAT THE ONSET OF POTENTIAL ILL HEALTH EFFECTS MAY BE DELAYED. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5126 WARNING AVOID INHALING FUEL VAPORS. INHALING TOO MUCH FUEL VAPOR CAN LEAD TO EYE AND RESPIRATORY TRACT IRRITATION. IN SEVERE CASES, EXCESSIVE OR PROLONGED BREATHING OF FUEL VAPORS CAN CAUSE SERIOUS ILLNESS AND PERMANENT INJURY SUCH AS BLINDNESS. WARNING AVOID GETTING GASOLINE IN YOUR EYES. IF YOU GET ANY FUEL IN YOUR EYES, REMOVE CONTRACT LENSES (IF WORN), FLUSH IMMEDIATELY WITH PLENTY OF WATER FOR AT LEAST 15 MINUTES AND SEEK MEDICAL ATTENTION. WARNING IF YOU GET ANY FUEL ON YOUR SKIN, WASH WITH SOAP AND WATER. REPEATED OR PROLONGED SKIN CONTACT WITH FUEL LIQUID OR VAPOR CAUSES SKIN IRRITATION. WARNING DO NOT OPERATE ENGINE OR SMOKE WHILE REFUELING. Expedition 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Raise and support vehicle. 4. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 5. Disconnect fuel filler and vent hoses from fuel tank. Refer to Figure 1. 6. Disconnect rear EVAP hose from top of fuel tank. See Figure 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5127 7. Support fuel tank with adjustable jack. 8. Remove fuel tank straps retaining bolts. The skid plate, fuel tank and straps will be removed as an assembly. 9. Slightly lower fuel tank. 10. Disconnect fuel supply and return lines from top of fuel tank. See Figure 2. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5128 11. Disconnect fuel pump electrical connector, located between the side of the fuel tank and the frame rail. See Figure 3. 12. Slightly lower fuel tank again. 13. Disconnect front EVAP hose from top of fuel tank. 14. Remove fuel tank from vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5129 15. Clean area around fuel pump to prevent foreign material from entering fuel tank. Refer to Figure 4. 16. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel pump during reassembly. 17. Remove fuel pump lock-ring, then remove fuel pump. See Figure 4. 18. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5130 19. Disconnect fuel sender electrical connectors. Refer to Figure 5. 20. Remove fuel sender retaining screws, then remove fuel sender. See Figure 5. 21. Install new fuel sender on fuel pump. Tighten screws to 2 Nm (18 lb/in). 22. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 23. Clean fuel pump-to-gas tank mating surface. 24. Install new seal onto fuel pump-to-gas tank mating surface. 25. Install fuel pump. Align marks made during disassembly. Tighten lock-ring to 44 Nm (33 lb/ft). 26. Position fuel tank under vehicle. 27. Raise fuel tank enough to connect front EVAP hose. 28. Connect front EVAP hose. 29. Raise fuel tank enough to connect fuel lines. 30. Connect fuel supply and return lines. 31. Connect fuel pump electrical connector. 32. Raise fuel tank to installed position. 33. Install fuel tank strap retaining bolts. Tighten bolts to 46-63 Nm (33-46 lb/ft). 34. Remove jack. 35. Connect rear EVAP hose to top of fuel tank. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5131 36. Connect fuel filler and vent hoses to fuel tank. 37. Refill fuel tank. It may be necessary to refill fuel tank before connecting filler hose. 38. Lower vehicle. 39. Connect battery negative cable, then remove memory saver. 40. Stan and run engine. 41. Raise vehicle. 42. Inspect fuel system for leaks. 43. Lower vehicle. Explorer/Mountaineer 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Raise and support vehicle. 4. Remove skid plate retaining bolts, then the skid plate. 5. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 6. Support fuel tank with adjustable jack. 7. Disconnect fuel filler and vent hoses from fuel tank. 8. Remove fuel tank strap retaining bolt. 9. Remove fuel tank-to-front support bracket retaining bolts. 10. Slightly lower fuel tank. Push fuel tank back until lip of tank clears support bracket. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5132 11. Disconnect fuel supply, return and vapor lines from top of fuel tank. See Figure 6. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5133 12. Disconnect fuel pump electrical connector, located in frame rail. See Figure 7. 13. Remove fuel tank from vehicle. 14. Disconnect fuel tank pressure transducer electrical connector. Refer to Figure 8. 15. Clean area around fuel pump to prevent foreign material from entering fuel tank. 16. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel pump during assembly. 17. Remove fuel pump retaining screws, then remove fuel pump. See Figure 8. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5134 18. Disconnect fuel sender electrical connectors. Refer to Figure 9. 19. Remove fuel sender retaining screws, then remove fuel sender. See Figure 9. 20. Install new fuel sender on fuel pump. Tighten screws to 2 Nm (18 lb/in). 21. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 22. Clean fuel pump-to-gas tank mating surface. 23. Install fuel pump. Align marks made during disassembly. Tighten retaining screws to 9-12 Nm (80-107 lb/in). 24. Connect fuel tank pressure transducer electrical connector. 25. Position fuel tank under vehicle. 26. Raise fuel tank enough to connect fuel lines. 27. Connect fuel supply and return lines. 28. Connect fuel pump electrical connector. 29. Position fuel tank in installed position. 30. Install fuel tank-to-front support bracket retaining bolts. Tighten bolts to 34-46 Nm (25-34 lb/ft). 31. Install fuel tank strap retaining bolt. Tighten bolts to 34-46 Nm (25-34 lb/ft). 32. Remove jack. 33. Connect fuel filler and vent hoses to fuel tank. 34. Install skid plate. Torque retaining bolts to 34-46 Nm (25-34 lb/ft). 35. Lower vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5135 36. Fill fuel tank. 37. Connect battery negative cable, then remove memory saver. 38. Start and run engine. 39. Raise vehicle. 40. Inspect fuel system for leaks. 41. Lower vehicle. Mustang 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 4. Remove fuel filler pipe retainers from gas cap side of fuel filler pipe. 5. Raise and support vehicle. 6. Remove screw retaining fuel filler pipe retainer to fuel tank flange.Refer to Figure 10. 7. Remove fuel filler pipe rubber weather boot from inner fender well. See Figure 10. 8. Support fuel tank with adjustable jack. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5136 9. Disconnect fuel pump electrical connector. See Figure 11. 10. Remove fuel tank straps retaining bolts. 11. Slightly lower fuel tank. 12. With an assistant's help, remove filler pipe from fuel tank. The filler pipe is friction fit into the fuel tank, the filler pipe will have to be walked out of the fuel tank. See Figure 12. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5137 13. Disconnect fuel supply, return and vapor lines. See Figure 13. 14. Disconnect fuel sender electrical connector. Refer to Figure 14. 15. Remove fuel tank from vehicle. 16. Clean area around fuel sender to prevent foreign material from entering fuel tank. 17. Place alignment mark across fuel sender and fuel tank. This will assure correct alignment of fuel sender during assembly. 18. Remove fuel sender lock-ring. See Figure 14. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5138 19. Remove and discard fuel sender. 20. Remove and discard fuel sender seal. 21. Lubricate and install new fuel sender seal. 22. Install new fuel sender. Align mark made during disassembly. Tighten lock ring until it contact stops. 23. Connect fuel sender electrical connector. 24. Raise fuel tank enough to connect fuel lines. 25. Connect fuel supply, return and vapor lines. 26. Install fuel filler pipe in fuel tank. 27. Position fuel tank in installed position. 28. Install fuel tank straps. Tighten retaining bolts to 30-40 Nm (22-30 lb/ft). 29. Remove adjustable jack. 30. Connect fuel pump electrical connector. 31. Install fuel filler pipe rubber weather boot to inner fender well. 32. Install screw retaining fuel filler pipe retainer to fuel tank flange. Tighten screw to 7.3-9.0 Nm (65-80 lb/in). 33. Lower vehicle. 34. Install fuel filler pipe retainers to gas cap side of fuel filler pipe. 35. Fill fuel tank. 36. Connect battery negative cable, then remove memory saver. 37. Start and run engine. 38. Raise vehicle. 39. Inspect fuel system for leaks. 40. Lower vehicle. Taurus/Sable 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 4. Raise and support vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5139 5. Disconnect fuel filler and vent hoses from fuel tank. See Figure 15. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5140 6. Disconnect fuel supply and return lines. Refer to Figure 16. 7. Disconnect fuel pump electrical connector. See Figure 16. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5141 8. Disconnect fuel vapor line. See Figure 17. 9. Support fuel tank with adjustable jack. 10. Remove fuel tank strap retaining bolts. 11. Remove fuel tank from vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5142 12. Detach fuel pump wiring harness and fuel lines from fuel tank. Refer to Figure 18. 13. Clean area around fuel pump to prevent foreign material from entering fuel tank. 14. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel pump during assembly. 15. Disconnect fuel pressure transducer electrical connector. See Figure 18. 16. Remove fuel pump lock-ring. 17. Remove fuel pump. 18. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5143 19. Disconnect fuel sender electrical connectors. Refer to Figure 19. 20. Remove fuel sender retaining screw, then remove fuel sender. See Figure 19. 21. Install new fuel sender on fuel pump. Tighten screw to 1 Nm (9 lb/in). 22. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 23. Clean fuel pump-to-gas tank mating surface. 24. Lubricate and install new fuel pump gasket. 25. Install fuel pump. Align marks made during disassembly. Tighten lock ring until it contacts stops. 26. Install fuel pump wiring harness and fuel lines on fuel tank assembly. 27. Connect fuel pressure transducer electrical connector. 28. Install fuel tank in vehicle. Tighten fuel tank straps to 30-40 Nm (22-30 lb/ft). 29. Remove adjustable jack. 30. Connect fuel pump electrical connector. 31. Connect fuel supply, return and vapor lines. 32. Connect fuel filler and vent hoses to fuel tank. 33. Lower vehicle. 34. Fill fuel tank. 35. Connect battery negative cable, then remove memory saver. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5144 36. Start and run engine. 37. Raise vehicle. 38. Inspect fuel system for leaks. 39. Lower vehicle. Windstar 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 4. Raise and support vehicle. 5. Support fuel tank with adjustable jack. 6. Disconnect fuel filler and vent hoses from fuel tank. 7. Disconnect fuel supply, return and vapor lines. See Figure 20. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5145 8. Disconnect fuel pump electrical connector. See Figure 21. 9. Remove fuel tank straps retaining bolts. 10. Remove fuel tank from vehicle. 11. Clean area around fuel pump to prevent foreign material from entering fuel tank. 12. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel during assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5146 13. Detach fuel lines from routing clips and tie strap. See Figure 22. 14. Remove fuel pump lock-ring. 15. Remove fuel pump. 16. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5147 17. Disconnect fuel sender electrical connectors. Refer to Figure 23. 18. Remove fuel sender retaining screw, then remove fuel sender. See Figure 23. 19. Install new fuel sender on fuel pump. Tighten screw to 1 Nm (9 lb/in). 20. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 21. Clean fuel pump-to-gas tank mating surface. 22. Install new fuel pump gasket. 23. Install fuel pump. Align marks made during disassembly. Tighten lock ring until it contact stops. 24. Attach fuel lines to routing clips and install tie strap. Connect fuel lines to fuel pump. Connect electrical connector to pump/sender. 25. Install fuel tank in vehicle. Tighten fuel tank straps to 41-54 Nm (31-39 lb/ft). 26. Connect fuel pump electrical connector. 27. Connect fuel supply, return and vapor lines. 28. Connect fuel filler and vent hoses to fuel tank. 29. Remove adjustable jack. 30. Lower vehicle. 31. Fill fuel tank. 32. Connect battery negative cable, then remove memory saver. 33. Start and run engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5148 34. Raise vehicle. 35. Inspect fuel system for leaks. 36. Lower vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5149 Supplement # 1 - Attachment II LABOR ALLOWANCES Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5150 PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order fuel sender assemblies and the gaskets through normal processing channels. PART NUMBER/DESCRIPTION Fuel Sender Assembly - NOTE: Some of the following applications will require gaskets to be ordered in addition to the sender assemblies. NOTE: Kit Codes "AA" & "BB" are not used. Warning For 1997 Expedition FUEL SENDER REPLACEMENT SUPPLEMENT FOR 1997 EXPEDITION WARNING DO NOT SWALLOW GASOLINE, THESE FUELS ARE HIGHLY TOXIC AND IF SWALLOWED CAN CAUSE DEATH OR PERMANENT INJURY, SWALLOWING METHANOL CAN ALSO CAUSE BLINDNESS. CALL A PHYSICIAN IMMEDIATELY TO TREAT ANYONE WHO HAS SWALLOWED FUEL METHANOL OR FUEL ETHANOL. VOMITING SHOULD BE INDUCED BY OR UNDER THE DIRECTION OF A PHYSICIAN OR POISON CONTROL CENTER. BE AWARE THAT THE ONSET OF POTENTIAL ILL HEALTH EFFECTS MAY BE DELAYED. WARNING AVOID INHALING FUEL VAPORS. INHALING TOO MUCH FUEL VAPOR CAN LEAD TO EYE AND RESPIRATORY TRACT IRRITATION. IN SEVERE CASES, EXCESSIVE OR PROLONGED BREATHING OF FUEL VAPORS CAN CAUSE SERIOUS ILLNESS AND PERMANENT INJURY SUCH AS BLINDNESS. WARNING AVOID GETTING GASOLINE IN YOUR EYES. IF YOU GET ANY FUEL IN YOUR EYES, REMOVE CONTACT LENSES (IF WORN), FLUSH IMMEDIATELY WITH PLENTY OF WATER FOR AT LEAST 15 MINUTES AND SEEK MEDICAL ATTENTION. WARNING IF YOU GET ANY FUEL ON YOUR SKIN, WASH WITH SOAP AND WATER. REPEATED OR PROLONGED SKIN CONTACT WITH FUEL LIQUID OR VAPOR CAUSES SKIN IRRITATION. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5151 WARNING DO NOT OPERATE ENGINE OR SMOKE WHILE REFUELING. Expedition 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Raise and support vehicle. 4. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 5. Disconnect fuel filler and vent hoses from fuel tank. Refer to Figure 1. 6. Disconnect rear EVAP hose from top of fuel tank. See Figure 1. 7. Support fuel tank with adjustable jack. 8. Remove fuel tank straps retaining bolts. The skid plate, fuel tank and straps will be removed as an assembly. 9. Slightly lower fuel tank. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5152 10. Disconnect fuel supply and return lines from top of fuel tank. See Figure 2. 11. Disconnect fuel pump electrical connector, located between the side of the fuel tank and the frame rail. See Figure 3. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5153 12. Slightly lower fuel tank again. 13. Disconnect front EVAP hose from top of fuel tank. 14. Remove fuel tank from vehicle. 15. Clean area around fuel pump to prevent foreign material from entering fuel tank. Refer to Figure 4. 16. Place alignment mark across fuel pump and fuel tank. This will correctly align the fuel pump during reassembly. 17. Remove fuel pump lock-ring, then remove fuel pump. See Figure 4. 18. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5154 19. Disconnect fuel sender electrical connectors. Refer to Figure 5. 20. Remove fuel sender retaining screws, then remove fuel sender. See Figure 5. NOTE: On some vehicles this step may have already been performed. CAUTION Do not cut the main 14 gauge pump ground wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5155 21. Cut a section out of the 18 gauge black grounding wire. See Figure 6. Discard removed black wire. 22. Install new fuel sender on the fuel pump. Tighten screws to 2 Nm (18 lb/in). Note the revised orientation of the float. NOTE: There are two (2) different terminal end types used on the fuel sender ground wire, a box terminal or a ring terminal. These terminal ends are connected to different locations on the fuel sender. 23. Connect fuel sender electrical connectors as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5156 ^ Connect box type terminal end ground wire to location shown in Figure 7. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5157 ^ Connect ring type terminal end ground wire to location shown in Figure 8. ^ Reconnect yellow wire to pump sending unit harness. 24. Clean fuel pump-to-gas tank mating surface. 25. Install new seal onto fuel pump-to-gas tank mating surface. 26. Install fuel pump. Align marks made during disassembly. Tighten lock-ring to 44 Nm (33 lb/ft). 27. Position fuel tank under vehicle. 28. Raise fuel tank enough to connect front EVAP hose. 29. Connect front EVAP hose. 30. Raise fuel tank enough to connect fuel lines. 31. Connect fuel supply and return lines. 32. Connect fuel pump electrical connector. 33. Raise fuel tank to installed position. 34. Install fuel tank strap retaining bolts. Tighten bolts to 46-63 Nm (33-46 lb/ft). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5158 35. Remove jack. 36. Connect rear EVAP hose to top of fuel tank. 37. Connect fuel filler and vent hoses to fuel tank. 38. Refill fuel tank. It may be necessary to refill fuel tank before connecting filler hose. 39. Lower vehicle. 40. Connect battery negative cable, then remove memory saver. 41. Stan and run engine. 42. Raise vehicle. 43. Inspect fuel system for leaks. 44. Lower vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest: > 97-9-16 > Apr > 97 > Fuel Gauge - Erratic and/or Inaccurate Readings Fuel Gauge Sender: Customer Interest Fuel Gauge - Erratic and/or Inaccurate Readings Article No. 97-9-16 04/28/97 GAUGES - FUEL - ERRATIC AND/OR INACCURATE READINGS - VEHICLES BUILT THROUGH 3/97 LIGHT TRUCK: 1997 EXPEDITION ISSUE: The fuel gauge may operate erratically and/or have inaccurate readings. This may be caused by the sensing float being positioned at the extreme aft of the fuel tank. ACTION: Replace the fuel pump and sender assembly with a revised pump and sender. The revised pump and sender has a repositioned sensor assembly to bring the float assembly closer to the center of the fuel tank. This should reduce the possibility of inaccurate and erratic readings. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the fuel tank as outlined in Section 310-01 in the 1997 Expedition Workshop Manual. 2. Remove the fuel pump and sender assembly as outlined in Section 310-01 of the Workshop Manual. NOTE: THERE IS NO NEED TO REMOVE THE SENDING UNIT FROM THE REMOVED PUMP. THE REPLACEMENT PUMP HAS A NEW SENDER FITTED ALREADY. THIS SENDER IS ORIENTED DIFFERENTLY FROM THE REMOVED PART. THIS WILL PUT THE FLOAT CLOSER TO THE CENTER OF THE TANK. 3. Remove the pressure transducer from the removed pump and install it onto the new pump. Make sure the electrical connection is made. 4. Using a new green seal (included with the pump), reinstall the pump and sender into the tank as outlined in Section 310-01 of the Workshop Manual. 5. Reinstall the fuel tank as outlined in Section 310-01 of the Workshop Manual. NOTE: WHEN THE BATTERY IS DISCONNECTED AND RECONNECTED, SOME ABNORMAL DRIVE SYMPTOMS MAY OCCUR WHILE THE VEHICLE RELEARNS ITS ADAPTIVE STRATEGY. THE VEHICLE MAY NEED TO BE DRIVEN 16 km (10 MILES) OR MORE TO RELEARN THE STRATEGY. PART NUMBER PART NAME F75Z-9H307-KC Fuel Pump And Sender Assembly (4X4) F75Z-9H307-LC Fuel Pump And Sender Assembly (4X2 Normal Suspension) F75Z-9H307-MC Fuel Pump And Sender Assembly (4X2 Air Suspension) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 970916A Replace Fuel Pump And 1.5 Hrs. Sender Assembly DEALER CODING CONDITION BASIC PART NO. CODE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest: > 97-9-16 > Apr > 97 > Fuel Gauge - Erratic and/or Inaccurate Readings > Page 5164 9K007 36 OASIS CODES: 204000, 204200 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly Technical Service Bulletin # 97B17 Date: 980201 Campaign - Fuel Gauge/Sender Assembly 97517 OWNER NOTIFICATION PROGRAM Fuel Gauge/Sender Assembly Replacement Original - February, 1998 Dealer Letter Attachment I ^ Administrative Information ^ Refund Codes Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Supplement # 1 - April, 1998 Supplement # 2 - November, 1998 Revised Expiration Date For Owner Notification Program 98B17 - Fuel Gauge/sender Replacement ^ IMPORTANT INFORMATION OWNER NOTIFICATION PROGRAM 97B17 EXPIRATION DATE ^ Attachments not Applicable ^ Customer Notification Letter not Applicable Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5170 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Affected vehicles on the enclosed list. ^ Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5171 Enter claims using DWE. See ACESII Manual, Sections 5 and 6. OWNER REFUNDS See ACESII Manual, Section 3-63 for submission procedures. For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Program Code - 97B17 Misc. Expense - REFUND Misc. Expense - ADMIN. Misc. Expense - 0.2 Hr. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order fuel sender assemblies and the gaskets through normal processing channels. PART NUMBER/DESCRIPTION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5172 Fuel Sender Assembly - NOTE: Some of the following applications will require gaskets to be ordered in addition to the sender assemblies. DEALER PRICE For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. CLAIMS PREPARATION Enter using DWE. Use code information shown below: ^ Program Code - 97B17 ^ Labor Operation Code - See Above See Sections 5 and 6 of the ACESII Manual for detailed instructions Affected Vehicle and Warning Information AFFECTED VEHICLES: CERTAIN 1997 TAURUS/SABLE, EXPLORER/MOUNTAINEER, EXPEDITION, MUSTANG AND 1998 WINDSTAR WARNING DO NOT SWALLOW GASOLINE, THESE FUELS ARE HIGHLY TOXIC AND IF SWALLOWED CAN CAUSE DEATH OR PERMANENT INJURY, SWALLOWING METHANOL CAN ALSO CAUSE BLINDNESS. CALL A PHYSICIAN IMMEDIATELY TO TREAT ANYONE WHO HAS SWALLOWED FUEL METHANOL OR FUEL ETHANOL. VOMITING SHOULD BE INDUCED BY OR UNDER THE DIRECTION OF A PHYSICIAN OR POISON CONTROL CENTER. BE AWARE THAT THE ONSET OF POTENTIAL ILL HEALTH EFFECTS MAY BE DELAYED. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5173 WARNING AVOID INHALING FUEL VAPORS. INHALING TOO MUCH FUEL VAPOR CAN LEAD TO EYE AND RESPIRATORY TRACT IRRITATION. IN SEVERE CASES, EXCESSIVE OR PROLONGED BREATHING OF FUEL VAPORS CAN CAUSE SERIOUS ILLNESS AND PERMANENT INJURY SUCH AS BLINDNESS. WARNING AVOID GETTING GASOLINE IN YOUR EYES. IF YOU GET ANY FUEL IN YOUR EYES, REMOVE CONTRACT LENSES (IF WORN), FLUSH IMMEDIATELY WITH PLENTY OF WATER FOR AT LEAST 15 MINUTES AND SEEK MEDICAL ATTENTION. WARNING IF YOU GET ANY FUEL ON YOUR SKIN, WASH WITH SOAP AND WATER. REPEATED OR PROLONGED SKIN CONTACT WITH FUEL LIQUID OR VAPOR CAUSES SKIN IRRITATION. WARNING DO NOT OPERATE ENGINE OR SMOKE WHILE REFUELING. Expedition 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Raise and support vehicle. 4. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 5. Disconnect fuel filler and vent hoses from fuel tank. Refer to Figure 1. 6. Disconnect rear EVAP hose from top of fuel tank. See Figure 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5174 7. Support fuel tank with adjustable jack. 8. Remove fuel tank straps retaining bolts. The skid plate, fuel tank and straps will be removed as an assembly. 9. Slightly lower fuel tank. 10. Disconnect fuel supply and return lines from top of fuel tank. See Figure 2. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5175 11. Disconnect fuel pump electrical connector, located between the side of the fuel tank and the frame rail. See Figure 3. 12. Slightly lower fuel tank again. 13. Disconnect front EVAP hose from top of fuel tank. 14. Remove fuel tank from vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5176 15. Clean area around fuel pump to prevent foreign material from entering fuel tank. Refer to Figure 4. 16. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel pump during reassembly. 17. Remove fuel pump lock-ring, then remove fuel pump. See Figure 4. 18. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5177 19. Disconnect fuel sender electrical connectors. Refer to Figure 5. 20. Remove fuel sender retaining screws, then remove fuel sender. See Figure 5. 21. Install new fuel sender on fuel pump. Tighten screws to 2 Nm (18 lb/in). 22. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 23. Clean fuel pump-to-gas tank mating surface. 24. Install new seal onto fuel pump-to-gas tank mating surface. 25. Install fuel pump. Align marks made during disassembly. Tighten lock-ring to 44 Nm (33 lb/ft). 26. Position fuel tank under vehicle. 27. Raise fuel tank enough to connect front EVAP hose. 28. Connect front EVAP hose. 29. Raise fuel tank enough to connect fuel lines. 30. Connect fuel supply and return lines. 31. Connect fuel pump electrical connector. 32. Raise fuel tank to installed position. 33. Install fuel tank strap retaining bolts. Tighten bolts to 46-63 Nm (33-46 lb/ft). 34. Remove jack. 35. Connect rear EVAP hose to top of fuel tank. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5178 36. Connect fuel filler and vent hoses to fuel tank. 37. Refill fuel tank. It may be necessary to refill fuel tank before connecting filler hose. 38. Lower vehicle. 39. Connect battery negative cable, then remove memory saver. 40. Stan and run engine. 41. Raise vehicle. 42. Inspect fuel system for leaks. 43. Lower vehicle. Explorer/Mountaineer 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Raise and support vehicle. 4. Remove skid plate retaining bolts, then the skid plate. 5. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 6. Support fuel tank with adjustable jack. 7. Disconnect fuel filler and vent hoses from fuel tank. 8. Remove fuel tank strap retaining bolt. 9. Remove fuel tank-to-front support bracket retaining bolts. 10. Slightly lower fuel tank. Push fuel tank back until lip of tank clears support bracket. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5179 11. Disconnect fuel supply, return and vapor lines from top of fuel tank. See Figure 6. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5180 12. Disconnect fuel pump electrical connector, located in frame rail. See Figure 7. 13. Remove fuel tank from vehicle. 14. Disconnect fuel tank pressure transducer electrical connector. Refer to Figure 8. 15. Clean area around fuel pump to prevent foreign material from entering fuel tank. 16. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel pump during assembly. 17. Remove fuel pump retaining screws, then remove fuel pump. See Figure 8. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5181 18. Disconnect fuel sender electrical connectors. Refer to Figure 9. 19. Remove fuel sender retaining screws, then remove fuel sender. See Figure 9. 20. Install new fuel sender on fuel pump. Tighten screws to 2 Nm (18 lb/in). 21. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 22. Clean fuel pump-to-gas tank mating surface. 23. Install fuel pump. Align marks made during disassembly. Tighten retaining screws to 9-12 Nm (80-107 lb/in). 24. Connect fuel tank pressure transducer electrical connector. 25. Position fuel tank under vehicle. 26. Raise fuel tank enough to connect fuel lines. 27. Connect fuel supply and return lines. 28. Connect fuel pump electrical connector. 29. Position fuel tank in installed position. 30. Install fuel tank-to-front support bracket retaining bolts. Tighten bolts to 34-46 Nm (25-34 lb/ft). 31. Install fuel tank strap retaining bolt. Tighten bolts to 34-46 Nm (25-34 lb/ft). 32. Remove jack. 33. Connect fuel filler and vent hoses to fuel tank. 34. Install skid plate. Torque retaining bolts to 34-46 Nm (25-34 lb/ft). 35. Lower vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5182 36. Fill fuel tank. 37. Connect battery negative cable, then remove memory saver. 38. Start and run engine. 39. Raise vehicle. 40. Inspect fuel system for leaks. 41. Lower vehicle. Mustang 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 4. Remove fuel filler pipe retainers from gas cap side of fuel filler pipe. 5. Raise and support vehicle. 6. Remove screw retaining fuel filler pipe retainer to fuel tank flange.Refer to Figure 10. 7. Remove fuel filler pipe rubber weather boot from inner fender well. See Figure 10. 8. Support fuel tank with adjustable jack. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5183 9. Disconnect fuel pump electrical connector. See Figure 11. 10. Remove fuel tank straps retaining bolts. 11. Slightly lower fuel tank. 12. With an assistant's help, remove filler pipe from fuel tank. The filler pipe is friction fit into the fuel tank, the filler pipe will have to be walked out of the fuel tank. See Figure 12. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5184 13. Disconnect fuel supply, return and vapor lines. See Figure 13. 14. Disconnect fuel sender electrical connector. Refer to Figure 14. 15. Remove fuel tank from vehicle. 16. Clean area around fuel sender to prevent foreign material from entering fuel tank. 17. Place alignment mark across fuel sender and fuel tank. This will assure correct alignment of fuel sender during assembly. 18. Remove fuel sender lock-ring. See Figure 14. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5185 19. Remove and discard fuel sender. 20. Remove and discard fuel sender seal. 21. Lubricate and install new fuel sender seal. 22. Install new fuel sender. Align mark made during disassembly. Tighten lock ring until it contact stops. 23. Connect fuel sender electrical connector. 24. Raise fuel tank enough to connect fuel lines. 25. Connect fuel supply, return and vapor lines. 26. Install fuel filler pipe in fuel tank. 27. Position fuel tank in installed position. 28. Install fuel tank straps. Tighten retaining bolts to 30-40 Nm (22-30 lb/ft). 29. Remove adjustable jack. 30. Connect fuel pump electrical connector. 31. Install fuel filler pipe rubber weather boot to inner fender well. 32. Install screw retaining fuel filler pipe retainer to fuel tank flange. Tighten screw to 7.3-9.0 Nm (65-80 lb/in). 33. Lower vehicle. 34. Install fuel filler pipe retainers to gas cap side of fuel filler pipe. 35. Fill fuel tank. 36. Connect battery negative cable, then remove memory saver. 37. Start and run engine. 38. Raise vehicle. 39. Inspect fuel system for leaks. 40. Lower vehicle. Taurus/Sable 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 4. Raise and support vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5186 5. Disconnect fuel filler and vent hoses from fuel tank. See Figure 15. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5187 6. Disconnect fuel supply and return lines. Refer to Figure 16. 7. Disconnect fuel pump electrical connector. See Figure 16. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5188 8. Disconnect fuel vapor line. See Figure 17. 9. Support fuel tank with adjustable jack. 10. Remove fuel tank strap retaining bolts. 11. Remove fuel tank from vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5189 12. Detach fuel pump wiring harness and fuel lines from fuel tank. Refer to Figure 18. 13. Clean area around fuel pump to prevent foreign material from entering fuel tank. 14. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel pump during assembly. 15. Disconnect fuel pressure transducer electrical connector. See Figure 18. 16. Remove fuel pump lock-ring. 17. Remove fuel pump. 18. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5190 19. Disconnect fuel sender electrical connectors. Refer to Figure 19. 20. Remove fuel sender retaining screw, then remove fuel sender. See Figure 19. 21. Install new fuel sender on fuel pump. Tighten screw to 1 Nm (9 lb/in). 22. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 23. Clean fuel pump-to-gas tank mating surface. 24. Lubricate and install new fuel pump gasket. 25. Install fuel pump. Align marks made during disassembly. Tighten lock ring until it contacts stops. 26. Install fuel pump wiring harness and fuel lines on fuel tank assembly. 27. Connect fuel pressure transducer electrical connector. 28. Install fuel tank in vehicle. Tighten fuel tank straps to 30-40 Nm (22-30 lb/ft). 29. Remove adjustable jack. 30. Connect fuel pump electrical connector. 31. Connect fuel supply, return and vapor lines. 32. Connect fuel filler and vent hoses to fuel tank. 33. Lower vehicle. 34. Fill fuel tank. 35. Connect battery negative cable, then remove memory saver. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5191 36. Start and run engine. 37. Raise vehicle. 38. Inspect fuel system for leaks. 39. Lower vehicle. Windstar 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 4. Raise and support vehicle. 5. Support fuel tank with adjustable jack. 6. Disconnect fuel filler and vent hoses from fuel tank. 7. Disconnect fuel supply, return and vapor lines. See Figure 20. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5192 8. Disconnect fuel pump electrical connector. See Figure 21. 9. Remove fuel tank straps retaining bolts. 10. Remove fuel tank from vehicle. 11. Clean area around fuel pump to prevent foreign material from entering fuel tank. 12. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel during assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5193 13. Detach fuel lines from routing clips and tie strap. See Figure 22. 14. Remove fuel pump lock-ring. 15. Remove fuel pump. 16. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5194 17. Disconnect fuel sender electrical connectors. Refer to Figure 23. 18. Remove fuel sender retaining screw, then remove fuel sender. See Figure 23. 19. Install new fuel sender on fuel pump. Tighten screw to 1 Nm (9 lb/in). 20. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 21. Clean fuel pump-to-gas tank mating surface. 22. Install new fuel pump gasket. 23. Install fuel pump. Align marks made during disassembly. Tighten lock ring until it contact stops. 24. Attach fuel lines to routing clips and install tie strap. Connect fuel lines to fuel pump. Connect electrical connector to pump/sender. 25. Install fuel tank in vehicle. Tighten fuel tank straps to 41-54 Nm (31-39 lb/ft). 26. Connect fuel pump electrical connector. 27. Connect fuel supply, return and vapor lines. 28. Connect fuel filler and vent hoses to fuel tank. 29. Remove adjustable jack. 30. Lower vehicle. 31. Fill fuel tank. 32. Connect battery negative cable, then remove memory saver. 33. Start and run engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5195 34. Raise vehicle. 35. Inspect fuel system for leaks. 36. Lower vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5196 Supplement # 1 - Attachment II LABOR ALLOWANCES Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5197 PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order fuel sender assemblies and the gaskets through normal processing channels. PART NUMBER/DESCRIPTION Fuel Sender Assembly - NOTE: Some of the following applications will require gaskets to be ordered in addition to the sender assemblies. NOTE: Kit Codes "AA" & "BB" are not used. Warning For 1997 Expedition FUEL SENDER REPLACEMENT SUPPLEMENT FOR 1997 EXPEDITION WARNING DO NOT SWALLOW GASOLINE, THESE FUELS ARE HIGHLY TOXIC AND IF SWALLOWED CAN CAUSE DEATH OR PERMANENT INJURY, SWALLOWING METHANOL CAN ALSO CAUSE BLINDNESS. CALL A PHYSICIAN IMMEDIATELY TO TREAT ANYONE WHO HAS SWALLOWED FUEL METHANOL OR FUEL ETHANOL. VOMITING SHOULD BE INDUCED BY OR UNDER THE DIRECTION OF A PHYSICIAN OR POISON CONTROL CENTER. BE AWARE THAT THE ONSET OF POTENTIAL ILL HEALTH EFFECTS MAY BE DELAYED. WARNING AVOID INHALING FUEL VAPORS. INHALING TOO MUCH FUEL VAPOR CAN LEAD TO EYE AND RESPIRATORY TRACT IRRITATION. IN SEVERE CASES, EXCESSIVE OR PROLONGED BREATHING OF FUEL VAPORS CAN CAUSE SERIOUS ILLNESS AND PERMANENT INJURY SUCH AS BLINDNESS. WARNING AVOID GETTING GASOLINE IN YOUR EYES. IF YOU GET ANY FUEL IN YOUR EYES, REMOVE CONTACT LENSES (IF WORN), FLUSH IMMEDIATELY WITH PLENTY OF WATER FOR AT LEAST 15 MINUTES AND SEEK MEDICAL ATTENTION. WARNING IF YOU GET ANY FUEL ON YOUR SKIN, WASH WITH SOAP AND WATER. REPEATED OR PROLONGED SKIN CONTACT WITH FUEL LIQUID OR VAPOR CAUSES SKIN IRRITATION. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5198 WARNING DO NOT OPERATE ENGINE OR SMOKE WHILE REFUELING. Expedition 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Raise and support vehicle. 4. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 5. Disconnect fuel filler and vent hoses from fuel tank. Refer to Figure 1. 6. Disconnect rear EVAP hose from top of fuel tank. See Figure 1. 7. Support fuel tank with adjustable jack. 8. Remove fuel tank straps retaining bolts. The skid plate, fuel tank and straps will be removed as an assembly. 9. Slightly lower fuel tank. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5199 10. Disconnect fuel supply and return lines from top of fuel tank. See Figure 2. 11. Disconnect fuel pump electrical connector, located between the side of the fuel tank and the frame rail. See Figure 3. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5200 12. Slightly lower fuel tank again. 13. Disconnect front EVAP hose from top of fuel tank. 14. Remove fuel tank from vehicle. 15. Clean area around fuel pump to prevent foreign material from entering fuel tank. Refer to Figure 4. 16. Place alignment mark across fuel pump and fuel tank. This will correctly align the fuel pump during reassembly. 17. Remove fuel pump lock-ring, then remove fuel pump. See Figure 4. 18. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5201 19. Disconnect fuel sender electrical connectors. Refer to Figure 5. 20. Remove fuel sender retaining screws, then remove fuel sender. See Figure 5. NOTE: On some vehicles this step may have already been performed. CAUTION Do not cut the main 14 gauge pump ground wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5202 21. Cut a section out of the 18 gauge black grounding wire. See Figure 6. Discard removed black wire. 22. Install new fuel sender on the fuel pump. Tighten screws to 2 Nm (18 lb/in). Note the revised orientation of the float. NOTE: There are two (2) different terminal end types used on the fuel sender ground wire, a box terminal or a ring terminal. These terminal ends are connected to different locations on the fuel sender. 23. Connect fuel sender electrical connectors as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5203 ^ Connect box type terminal end ground wire to location shown in Figure 7. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5204 ^ Connect ring type terminal end ground wire to location shown in Figure 8. ^ Reconnect yellow wire to pump sending unit harness. 24. Clean fuel pump-to-gas tank mating surface. 25. Install new seal onto fuel pump-to-gas tank mating surface. 26. Install fuel pump. Align marks made during disassembly. Tighten lock-ring to 44 Nm (33 lb/ft). 27. Position fuel tank under vehicle. 28. Raise fuel tank enough to connect front EVAP hose. 29. Connect front EVAP hose. 30. Raise fuel tank enough to connect fuel lines. 31. Connect fuel supply and return lines. 32. Connect fuel pump electrical connector. 33. Raise fuel tank to installed position. 34. Install fuel tank strap retaining bolts. Tighten bolts to 46-63 Nm (33-46 lb/ft). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5205 35. Remove jack. 36. Connect rear EVAP hose to top of fuel tank. 37. Connect fuel filler and vent hoses to fuel tank. 38. Refill fuel tank. It may be necessary to refill fuel tank before connecting filler hose. 39. Lower vehicle. 40. Connect battery negative cable, then remove memory saver. 41. Stan and run engine. 42. Raise vehicle. 43. Inspect fuel system for leaks. 44. Lower vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97-9-16 > Apr > 97 > Fuel Gauge - Erratic and/or Inaccurate Readings Fuel Gauge Sender: All Technical Service Bulletins Fuel Gauge - Erratic and/or Inaccurate Readings Article No. 97-9-16 04/28/97 GAUGES - FUEL - ERRATIC AND/OR INACCURATE READINGS - VEHICLES BUILT THROUGH 3/97 LIGHT TRUCK: 1997 EXPEDITION ISSUE: The fuel gauge may operate erratically and/or have inaccurate readings. This may be caused by the sensing float being positioned at the extreme aft of the fuel tank. ACTION: Replace the fuel pump and sender assembly with a revised pump and sender. The revised pump and sender has a repositioned sensor assembly to bring the float assembly closer to the center of the fuel tank. This should reduce the possibility of inaccurate and erratic readings. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the fuel tank as outlined in Section 310-01 in the 1997 Expedition Workshop Manual. 2. Remove the fuel pump and sender assembly as outlined in Section 310-01 of the Workshop Manual. NOTE: THERE IS NO NEED TO REMOVE THE SENDING UNIT FROM THE REMOVED PUMP. THE REPLACEMENT PUMP HAS A NEW SENDER FITTED ALREADY. THIS SENDER IS ORIENTED DIFFERENTLY FROM THE REMOVED PART. THIS WILL PUT THE FLOAT CLOSER TO THE CENTER OF THE TANK. 3. Remove the pressure transducer from the removed pump and install it onto the new pump. Make sure the electrical connection is made. 4. Using a new green seal (included with the pump), reinstall the pump and sender into the tank as outlined in Section 310-01 of the Workshop Manual. 5. Reinstall the fuel tank as outlined in Section 310-01 of the Workshop Manual. NOTE: WHEN THE BATTERY IS DISCONNECTED AND RECONNECTED, SOME ABNORMAL DRIVE SYMPTOMS MAY OCCUR WHILE THE VEHICLE RELEARNS ITS ADAPTIVE STRATEGY. THE VEHICLE MAY NEED TO BE DRIVEN 16 km (10 MILES) OR MORE TO RELEARN THE STRATEGY. PART NUMBER PART NAME F75Z-9H307-KC Fuel Pump And Sender Assembly (4X4) F75Z-9H307-LC Fuel Pump And Sender Assembly (4X2 Normal Suspension) F75Z-9H307-MC Fuel Pump And Sender Assembly (4X2 Air Suspension) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 970916A Replace Fuel Pump And 1.5 Hrs. Sender Assembly DEALER CODING CONDITION BASIC PART NO. CODE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97-9-16 > Apr > 97 > Fuel Gauge - Erratic and/or Inaccurate Readings > Page 5210 9K007 36 OASIS CODES: 204000, 204200 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97-9-16 > Apr > 97 > Fuel Gauge - Erratic and/or Inaccurate Readings Fuel Gauge Sender: All Technical Service Bulletins Fuel Gauge - Erratic and/or Inaccurate Readings Article No. 97-9-16 04/28/97 GAUGES - FUEL - ERRATIC AND/OR INACCURATE READINGS - VEHICLES BUILT THROUGH 3/97 LIGHT TRUCK: 1997 EXPEDITION ISSUE: The fuel gauge may operate erratically and/or have inaccurate readings. This may be caused by the sensing float being positioned at the extreme aft of the fuel tank. ACTION: Replace the fuel pump and sender assembly with a revised pump and sender. The revised pump and sender has a repositioned sensor assembly to bring the float assembly closer to the center of the fuel tank. This should reduce the possibility of inaccurate and erratic readings. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the fuel tank as outlined in Section 310-01 in the 1997 Expedition Workshop Manual. 2. Remove the fuel pump and sender assembly as outlined in Section 310-01 of the Workshop Manual. NOTE: THERE IS NO NEED TO REMOVE THE SENDING UNIT FROM THE REMOVED PUMP. THE REPLACEMENT PUMP HAS A NEW SENDER FITTED ALREADY. THIS SENDER IS ORIENTED DIFFERENTLY FROM THE REMOVED PART. THIS WILL PUT THE FLOAT CLOSER TO THE CENTER OF THE TANK. 3. Remove the pressure transducer from the removed pump and install it onto the new pump. Make sure the electrical connection is made. 4. Using a new green seal (included with the pump), reinstall the pump and sender into the tank as outlined in Section 310-01 of the Workshop Manual. 5. Reinstall the fuel tank as outlined in Section 310-01 of the Workshop Manual. NOTE: WHEN THE BATTERY IS DISCONNECTED AND RECONNECTED, SOME ABNORMAL DRIVE SYMPTOMS MAY OCCUR WHILE THE VEHICLE RELEARNS ITS ADAPTIVE STRATEGY. THE VEHICLE MAY NEED TO BE DRIVEN 16 km (10 MILES) OR MORE TO RELEARN THE STRATEGY. PART NUMBER PART NAME F75Z-9H307-KC Fuel Pump And Sender Assembly (4X4) F75Z-9H307-LC Fuel Pump And Sender Assembly (4X2 Normal Suspension) F75Z-9H307-MC Fuel Pump And Sender Assembly (4X2 Air Suspension) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 970916A Replace Fuel Pump And 1.5 Hrs. Sender Assembly DEALER CODING CONDITION BASIC PART NO. CODE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97-9-16 > Apr > 97 > Fuel Gauge - Erratic and/or Inaccurate Readings > Page 5216 9K007 36 OASIS CODES: 204000, 204200 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly Technical Service Bulletin # 97B17 Date: 980201 Campaign - Fuel Gauge/Sender Assembly 97517 OWNER NOTIFICATION PROGRAM Fuel Gauge/Sender Assembly Replacement Original - February, 1998 Dealer Letter Attachment I ^ Administrative Information ^ Refund Codes Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Supplement # 1 - April, 1998 Supplement # 2 - November, 1998 Revised Expiration Date For Owner Notification Program 98B17 - Fuel Gauge/sender Replacement ^ IMPORTANT INFORMATION OWNER NOTIFICATION PROGRAM 97B17 EXPIRATION DATE ^ Attachments not Applicable ^ Customer Notification Letter not Applicable Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5222 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Affected vehicles on the enclosed list. ^ Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5223 Enter claims using DWE. See ACESII Manual, Sections 5 and 6. OWNER REFUNDS See ACESII Manual, Section 3-63 for submission procedures. For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Program Code - 97B17 Misc. Expense - REFUND Misc. Expense - ADMIN. Misc. Expense - 0.2 Hr. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order fuel sender assemblies and the gaskets through normal processing channels. PART NUMBER/DESCRIPTION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5224 Fuel Sender Assembly - NOTE: Some of the following applications will require gaskets to be ordered in addition to the sender assemblies. DEALER PRICE For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. CLAIMS PREPARATION Enter using DWE. Use code information shown below: ^ Program Code - 97B17 ^ Labor Operation Code - See Above See Sections 5 and 6 of the ACESII Manual for detailed instructions Affected Vehicle and Warning Information AFFECTED VEHICLES: CERTAIN 1997 TAURUS/SABLE, EXPLORER/MOUNTAINEER, EXPEDITION, MUSTANG AND 1998 WINDSTAR WARNING DO NOT SWALLOW GASOLINE, THESE FUELS ARE HIGHLY TOXIC AND IF SWALLOWED CAN CAUSE DEATH OR PERMANENT INJURY, SWALLOWING METHANOL CAN ALSO CAUSE BLINDNESS. CALL A PHYSICIAN IMMEDIATELY TO TREAT ANYONE WHO HAS SWALLOWED FUEL METHANOL OR FUEL ETHANOL. VOMITING SHOULD BE INDUCED BY OR UNDER THE DIRECTION OF A PHYSICIAN OR POISON CONTROL CENTER. BE AWARE THAT THE ONSET OF POTENTIAL ILL HEALTH EFFECTS MAY BE DELAYED. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5225 WARNING AVOID INHALING FUEL VAPORS. INHALING TOO MUCH FUEL VAPOR CAN LEAD TO EYE AND RESPIRATORY TRACT IRRITATION. IN SEVERE CASES, EXCESSIVE OR PROLONGED BREATHING OF FUEL VAPORS CAN CAUSE SERIOUS ILLNESS AND PERMANENT INJURY SUCH AS BLINDNESS. WARNING AVOID GETTING GASOLINE IN YOUR EYES. IF YOU GET ANY FUEL IN YOUR EYES, REMOVE CONTRACT LENSES (IF WORN), FLUSH IMMEDIATELY WITH PLENTY OF WATER FOR AT LEAST 15 MINUTES AND SEEK MEDICAL ATTENTION. WARNING IF YOU GET ANY FUEL ON YOUR SKIN, WASH WITH SOAP AND WATER. REPEATED OR PROLONGED SKIN CONTACT WITH FUEL LIQUID OR VAPOR CAUSES SKIN IRRITATION. WARNING DO NOT OPERATE ENGINE OR SMOKE WHILE REFUELING. Expedition 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Raise and support vehicle. 4. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 5. Disconnect fuel filler and vent hoses from fuel tank. Refer to Figure 1. 6. Disconnect rear EVAP hose from top of fuel tank. See Figure 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5226 7. Support fuel tank with adjustable jack. 8. Remove fuel tank straps retaining bolts. The skid plate, fuel tank and straps will be removed as an assembly. 9. Slightly lower fuel tank. 10. Disconnect fuel supply and return lines from top of fuel tank. See Figure 2. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5227 11. Disconnect fuel pump electrical connector, located between the side of the fuel tank and the frame rail. See Figure 3. 12. Slightly lower fuel tank again. 13. Disconnect front EVAP hose from top of fuel tank. 14. Remove fuel tank from vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5228 15. Clean area around fuel pump to prevent foreign material from entering fuel tank. Refer to Figure 4. 16. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel pump during reassembly. 17. Remove fuel pump lock-ring, then remove fuel pump. See Figure 4. 18. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5229 19. Disconnect fuel sender electrical connectors. Refer to Figure 5. 20. Remove fuel sender retaining screws, then remove fuel sender. See Figure 5. 21. Install new fuel sender on fuel pump. Tighten screws to 2 Nm (18 lb/in). 22. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 23. Clean fuel pump-to-gas tank mating surface. 24. Install new seal onto fuel pump-to-gas tank mating surface. 25. Install fuel pump. Align marks made during disassembly. Tighten lock-ring to 44 Nm (33 lb/ft). 26. Position fuel tank under vehicle. 27. Raise fuel tank enough to connect front EVAP hose. 28. Connect front EVAP hose. 29. Raise fuel tank enough to connect fuel lines. 30. Connect fuel supply and return lines. 31. Connect fuel pump electrical connector. 32. Raise fuel tank to installed position. 33. Install fuel tank strap retaining bolts. Tighten bolts to 46-63 Nm (33-46 lb/ft). 34. Remove jack. 35. Connect rear EVAP hose to top of fuel tank. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5230 36. Connect fuel filler and vent hoses to fuel tank. 37. Refill fuel tank. It may be necessary to refill fuel tank before connecting filler hose. 38. Lower vehicle. 39. Connect battery negative cable, then remove memory saver. 40. Stan and run engine. 41. Raise vehicle. 42. Inspect fuel system for leaks. 43. Lower vehicle. Explorer/Mountaineer 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Raise and support vehicle. 4. Remove skid plate retaining bolts, then the skid plate. 5. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 6. Support fuel tank with adjustable jack. 7. Disconnect fuel filler and vent hoses from fuel tank. 8. Remove fuel tank strap retaining bolt. 9. Remove fuel tank-to-front support bracket retaining bolts. 10. Slightly lower fuel tank. Push fuel tank back until lip of tank clears support bracket. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5231 11. Disconnect fuel supply, return and vapor lines from top of fuel tank. See Figure 6. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5232 12. Disconnect fuel pump electrical connector, located in frame rail. See Figure 7. 13. Remove fuel tank from vehicle. 14. Disconnect fuel tank pressure transducer electrical connector. Refer to Figure 8. 15. Clean area around fuel pump to prevent foreign material from entering fuel tank. 16. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel pump during assembly. 17. Remove fuel pump retaining screws, then remove fuel pump. See Figure 8. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5233 18. Disconnect fuel sender electrical connectors. Refer to Figure 9. 19. Remove fuel sender retaining screws, then remove fuel sender. See Figure 9. 20. Install new fuel sender on fuel pump. Tighten screws to 2 Nm (18 lb/in). 21. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 22. Clean fuel pump-to-gas tank mating surface. 23. Install fuel pump. Align marks made during disassembly. Tighten retaining screws to 9-12 Nm (80-107 lb/in). 24. Connect fuel tank pressure transducer electrical connector. 25. Position fuel tank under vehicle. 26. Raise fuel tank enough to connect fuel lines. 27. Connect fuel supply and return lines. 28. Connect fuel pump electrical connector. 29. Position fuel tank in installed position. 30. Install fuel tank-to-front support bracket retaining bolts. Tighten bolts to 34-46 Nm (25-34 lb/ft). 31. Install fuel tank strap retaining bolt. Tighten bolts to 34-46 Nm (25-34 lb/ft). 32. Remove jack. 33. Connect fuel filler and vent hoses to fuel tank. 34. Install skid plate. Torque retaining bolts to 34-46 Nm (25-34 lb/ft). 35. Lower vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5234 36. Fill fuel tank. 37. Connect battery negative cable, then remove memory saver. 38. Start and run engine. 39. Raise vehicle. 40. Inspect fuel system for leaks. 41. Lower vehicle. Mustang 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 4. Remove fuel filler pipe retainers from gas cap side of fuel filler pipe. 5. Raise and support vehicle. 6. Remove screw retaining fuel filler pipe retainer to fuel tank flange.Refer to Figure 10. 7. Remove fuel filler pipe rubber weather boot from inner fender well. See Figure 10. 8. Support fuel tank with adjustable jack. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5235 9. Disconnect fuel pump electrical connector. See Figure 11. 10. Remove fuel tank straps retaining bolts. 11. Slightly lower fuel tank. 12. With an assistant's help, remove filler pipe from fuel tank. The filler pipe is friction fit into the fuel tank, the filler pipe will have to be walked out of the fuel tank. See Figure 12. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5236 13. Disconnect fuel supply, return and vapor lines. See Figure 13. 14. Disconnect fuel sender electrical connector. Refer to Figure 14. 15. Remove fuel tank from vehicle. 16. Clean area around fuel sender to prevent foreign material from entering fuel tank. 17. Place alignment mark across fuel sender and fuel tank. This will assure correct alignment of fuel sender during assembly. 18. Remove fuel sender lock-ring. See Figure 14. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5237 19. Remove and discard fuel sender. 20. Remove and discard fuel sender seal. 21. Lubricate and install new fuel sender seal. 22. Install new fuel sender. Align mark made during disassembly. Tighten lock ring until it contact stops. 23. Connect fuel sender electrical connector. 24. Raise fuel tank enough to connect fuel lines. 25. Connect fuel supply, return and vapor lines. 26. Install fuel filler pipe in fuel tank. 27. Position fuel tank in installed position. 28. Install fuel tank straps. Tighten retaining bolts to 30-40 Nm (22-30 lb/ft). 29. Remove adjustable jack. 30. Connect fuel pump electrical connector. 31. Install fuel filler pipe rubber weather boot to inner fender well. 32. Install screw retaining fuel filler pipe retainer to fuel tank flange. Tighten screw to 7.3-9.0 Nm (65-80 lb/in). 33. Lower vehicle. 34. Install fuel filler pipe retainers to gas cap side of fuel filler pipe. 35. Fill fuel tank. 36. Connect battery negative cable, then remove memory saver. 37. Start and run engine. 38. Raise vehicle. 39. Inspect fuel system for leaks. 40. Lower vehicle. Taurus/Sable 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 4. Raise and support vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5238 5. Disconnect fuel filler and vent hoses from fuel tank. See Figure 15. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5239 6. Disconnect fuel supply and return lines. Refer to Figure 16. 7. Disconnect fuel pump electrical connector. See Figure 16. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5240 8. Disconnect fuel vapor line. See Figure 17. 9. Support fuel tank with adjustable jack. 10. Remove fuel tank strap retaining bolts. 11. Remove fuel tank from vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5241 12. Detach fuel pump wiring harness and fuel lines from fuel tank. Refer to Figure 18. 13. Clean area around fuel pump to prevent foreign material from entering fuel tank. 14. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel pump during assembly. 15. Disconnect fuel pressure transducer electrical connector. See Figure 18. 16. Remove fuel pump lock-ring. 17. Remove fuel pump. 18. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5242 19. Disconnect fuel sender electrical connectors. Refer to Figure 19. 20. Remove fuel sender retaining screw, then remove fuel sender. See Figure 19. 21. Install new fuel sender on fuel pump. Tighten screw to 1 Nm (9 lb/in). 22. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 23. Clean fuel pump-to-gas tank mating surface. 24. Lubricate and install new fuel pump gasket. 25. Install fuel pump. Align marks made during disassembly. Tighten lock ring until it contacts stops. 26. Install fuel pump wiring harness and fuel lines on fuel tank assembly. 27. Connect fuel pressure transducer electrical connector. 28. Install fuel tank in vehicle. Tighten fuel tank straps to 30-40 Nm (22-30 lb/ft). 29. Remove adjustable jack. 30. Connect fuel pump electrical connector. 31. Connect fuel supply, return and vapor lines. 32. Connect fuel filler and vent hoses to fuel tank. 33. Lower vehicle. 34. Fill fuel tank. 35. Connect battery negative cable, then remove memory saver. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5243 36. Start and run engine. 37. Raise vehicle. 38. Inspect fuel system for leaks. 39. Lower vehicle. Windstar 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 4. Raise and support vehicle. 5. Support fuel tank with adjustable jack. 6. Disconnect fuel filler and vent hoses from fuel tank. 7. Disconnect fuel supply, return and vapor lines. See Figure 20. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5244 8. Disconnect fuel pump electrical connector. See Figure 21. 9. Remove fuel tank straps retaining bolts. 10. Remove fuel tank from vehicle. 11. Clean area around fuel pump to prevent foreign material from entering fuel tank. 12. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel during assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5245 13. Detach fuel lines from routing clips and tie strap. See Figure 22. 14. Remove fuel pump lock-ring. 15. Remove fuel pump. 16. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5246 17. Disconnect fuel sender electrical connectors. Refer to Figure 23. 18. Remove fuel sender retaining screw, then remove fuel sender. See Figure 23. 19. Install new fuel sender on fuel pump. Tighten screw to 1 Nm (9 lb/in). 20. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 21. Clean fuel pump-to-gas tank mating surface. 22. Install new fuel pump gasket. 23. Install fuel pump. Align marks made during disassembly. Tighten lock ring until it contact stops. 24. Attach fuel lines to routing clips and install tie strap. Connect fuel lines to fuel pump. Connect electrical connector to pump/sender. 25. Install fuel tank in vehicle. Tighten fuel tank straps to 41-54 Nm (31-39 lb/ft). 26. Connect fuel pump electrical connector. 27. Connect fuel supply, return and vapor lines. 28. Connect fuel filler and vent hoses to fuel tank. 29. Remove adjustable jack. 30. Lower vehicle. 31. Fill fuel tank. 32. Connect battery negative cable, then remove memory saver. 33. Start and run engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5247 34. Raise vehicle. 35. Inspect fuel system for leaks. 36. Lower vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5248 Supplement # 1 - Attachment II LABOR ALLOWANCES Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5249 PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order fuel sender assemblies and the gaskets through normal processing channels. PART NUMBER/DESCRIPTION Fuel Sender Assembly - NOTE: Some of the following applications will require gaskets to be ordered in addition to the sender assemblies. NOTE: Kit Codes "AA" & "BB" are not used. Warning For 1997 Expedition FUEL SENDER REPLACEMENT SUPPLEMENT FOR 1997 EXPEDITION WARNING DO NOT SWALLOW GASOLINE, THESE FUELS ARE HIGHLY TOXIC AND IF SWALLOWED CAN CAUSE DEATH OR PERMANENT INJURY, SWALLOWING METHANOL CAN ALSO CAUSE BLINDNESS. CALL A PHYSICIAN IMMEDIATELY TO TREAT ANYONE WHO HAS SWALLOWED FUEL METHANOL OR FUEL ETHANOL. VOMITING SHOULD BE INDUCED BY OR UNDER THE DIRECTION OF A PHYSICIAN OR POISON CONTROL CENTER. BE AWARE THAT THE ONSET OF POTENTIAL ILL HEALTH EFFECTS MAY BE DELAYED. WARNING AVOID INHALING FUEL VAPORS. INHALING TOO MUCH FUEL VAPOR CAN LEAD TO EYE AND RESPIRATORY TRACT IRRITATION. IN SEVERE CASES, EXCESSIVE OR PROLONGED BREATHING OF FUEL VAPORS CAN CAUSE SERIOUS ILLNESS AND PERMANENT INJURY SUCH AS BLINDNESS. WARNING AVOID GETTING GASOLINE IN YOUR EYES. IF YOU GET ANY FUEL IN YOUR EYES, REMOVE CONTACT LENSES (IF WORN), FLUSH IMMEDIATELY WITH PLENTY OF WATER FOR AT LEAST 15 MINUTES AND SEEK MEDICAL ATTENTION. WARNING IF YOU GET ANY FUEL ON YOUR SKIN, WASH WITH SOAP AND WATER. REPEATED OR PROLONGED SKIN CONTACT WITH FUEL LIQUID OR VAPOR CAUSES SKIN IRRITATION. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5250 WARNING DO NOT OPERATE ENGINE OR SMOKE WHILE REFUELING. Expedition 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Raise and support vehicle. 4. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 5. Disconnect fuel filler and vent hoses from fuel tank. Refer to Figure 1. 6. Disconnect rear EVAP hose from top of fuel tank. See Figure 1. 7. Support fuel tank with adjustable jack. 8. Remove fuel tank straps retaining bolts. The skid plate, fuel tank and straps will be removed as an assembly. 9. Slightly lower fuel tank. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5251 10. Disconnect fuel supply and return lines from top of fuel tank. See Figure 2. 11. Disconnect fuel pump electrical connector, located between the side of the fuel tank and the frame rail. See Figure 3. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5252 12. Slightly lower fuel tank again. 13. Disconnect front EVAP hose from top of fuel tank. 14. Remove fuel tank from vehicle. 15. Clean area around fuel pump to prevent foreign material from entering fuel tank. Refer to Figure 4. 16. Place alignment mark across fuel pump and fuel tank. This will correctly align the fuel pump during reassembly. 17. Remove fuel pump lock-ring, then remove fuel pump. See Figure 4. 18. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5253 19. Disconnect fuel sender electrical connectors. Refer to Figure 5. 20. Remove fuel sender retaining screws, then remove fuel sender. See Figure 5. NOTE: On some vehicles this step may have already been performed. CAUTION Do not cut the main 14 gauge pump ground wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5254 21. Cut a section out of the 18 gauge black grounding wire. See Figure 6. Discard removed black wire. 22. Install new fuel sender on the fuel pump. Tighten screws to 2 Nm (18 lb/in). Note the revised orientation of the float. NOTE: There are two (2) different terminal end types used on the fuel sender ground wire, a box terminal or a ring terminal. These terminal ends are connected to different locations on the fuel sender. 23. Connect fuel sender electrical connectors as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5255 ^ Connect box type terminal end ground wire to location shown in Figure 7. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5256 ^ Connect ring type terminal end ground wire to location shown in Figure 8. ^ Reconnect yellow wire to pump sending unit harness. 24. Clean fuel pump-to-gas tank mating surface. 25. Install new seal onto fuel pump-to-gas tank mating surface. 26. Install fuel pump. Align marks made during disassembly. Tighten lock-ring to 44 Nm (33 lb/ft). 27. Position fuel tank under vehicle. 28. Raise fuel tank enough to connect front EVAP hose. 29. Connect front EVAP hose. 30. Raise fuel tank enough to connect fuel lines. 31. Connect fuel supply and return lines. 32. Connect fuel pump electrical connector. 33. Raise fuel tank to installed position. 34. Install fuel tank strap retaining bolts. Tighten bolts to 46-63 Nm (33-46 lb/ft). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 5257 35. Remove jack. 36. Connect rear EVAP hose to top of fuel tank. 37. Connect fuel filler and vent hoses to fuel tank. 38. Refill fuel tank. It may be necessary to refill fuel tank before connecting filler hose. 39. Lower vehicle. 40. Connect battery negative cable, then remove memory saver. 41. Stan and run engine. 42. Raise vehicle. 43. Inspect fuel system for leaks. 44. Lower vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications Idle Speed/Throttle Actuator - Electronic: Specifications Idle Air Control Valve Bolts (Step 1) 8-10 Nm Idle Air Control Valve Bolts (Step 2) 10-11 Nm Splash Shield Bolts 5.9-8.1 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 5261 Idle Speed/Throttle Actuator - Electronic: Locations The Idle Air Control Valve (IAC) is mounted to the upper intake manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 5262 Idle Speed/Throttle Actuator - Electronic: Description and Operation Purpose The Idle Air Control (IAC) valve is used to control engine idle speed and dashpot functions. Operation The idle air control valve allows air to bypass the throttle plate. The amount of air allowed to bypass the throttle plate, will be determined by the PCM and be controlled by a duty cycle signal. CAUTION: Cleaning the IAC valve is NOT recommended. The use of solvents may damage the IAC valve. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Service and Repair > Installation Idle Speed/Throttle Actuator - Electronic: Service and Repair Installation INSTALLATION NOTE:A new IAC valve gasket must be installed. 1. Install the IAC valve. 1 Position the IAC valve and gasket. 2 Install the bolts in two stages: 8-10 Nm (71-89 in lb) - 10-11 Nm (89-95 in lb) 2. Connect the throttle bypass hose and the IAC electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Service and Repair > Installation > Page 5265 3. Install the accelerator control splash shield. 4. Connect the battery ground cable Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Service and Repair > Installation > Page 5266 Idle Speed/Throttle Actuator - Electronic: Service and Repair Removal REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Remove the accelerator control splash shield. 1 Remove the accelerator splash shield bolts. 2 Remove the accelerator control splash shield from the vehicle. 3. Remove the Idle Air Control (IAC) valve. 1 Disconnect the electrical connector. 2 Disconnect the throttle bypass hose. 3 Remove the bolts. 4 Remove the IAC valve. 5 Remove and discard the IAC valve gasket. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations Inertia Fuel Shutoff Switch: Locations The inertia fuel shutoff switch is located under the RH cowl side trim (kick) panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 5270 Inertia Fuel Shutoff Switch: Service Precautions WARNING: Do not reset the Inertia Fuel Shutoff switch (IFS) switch until the complete fuel system has been inspected for leaks. Damage to the vehicle or personal injury may occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 5271 Inertia Fuel Shutoff Switch: Description and Operation Typical Inertia Fuel Shut-Off Switch Description The inertia fuel shutoff switch: - is used in conjunction with an electric fuel pump. - shuts off the fuel pump in the event of a collision. - consists of a steel ball held in place by a magnet. Operation When a sharp impact occurs: - the ball breaks loose from the magnet, rolls up a ramp and strikes a target plate which opens the electrical contacts of the inertia fuel shutoff switch and shuts off the fuel pump. - Once the inertia fuel shutoff switch is open, the inertia fuel shutoff switch must be manually reset before restarting the vehicle. If a collision occurs: - the electrical contacts in the inertia fuel shutoff switch open. - the fuel pump automatically shuts off, even if the engine does not stop running. - the engine will stop a few seconds after the fuel pump stops. - it is impossible to restart engine until the inertia fuel shutoff switch, located on the LH side lower back panel in the luggage compartment, is manually reset. NOTE:In the reset position, the button can be pressed an additional 1.59 mm (0.0625 inch) against a spring. This is a normal condition. WARNING: Do not reset the inertia fuel shutoff switch until the complete fuel system has been inspected for leaks or damage to vehicle or personal injury may occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 5272 Inertia Fuel Shutoff Switch: Testing and Inspection To avoid potential misdiagnosis and the unnecessary replacement of components, it is recommended that diagnosis and testing begin with Diagnostic Routines (Diagnosis by Symptom) at the Powertrain Management level. The Diagnostic Routines will lead the technician through the logical and methodical testing of a "specific" subsystem and it's related wiring and components. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 5273 Inertia Fuel Shutoff Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Remove the RH cowl side trim panel. 3. Disconnect the inertia fuel shutoff switch electrical connector. 4. Remove the inertia fuel shutoff switch. 1 Remove inertia switch bolts. 2 Remove the inertia fuel shutoff switch. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 5274 To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Description and Operation Intake Air Duct: Description and Operation PURPOSE The intake air duct provides metered, filtered air to the engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Description and Operation > Page 5278 Intake Air Duct: Service and Repair REMOVAL 1. Remove the accelerator control splash shield. 1 Remove the three accelerator control splash shield bolts. 2 Remove the accelerator control splash shield. 2. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 3. Disconnect the (A) positive crankcase ventilation hose and the (B) idle air control valve inlet tube. 4. Loosen the air cleaner outlet tube hose clamp screws and remove the air cleaner outlet tube. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Description and Operation > Page 5279 CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5283 Power Distribution Box The Powertrain Control Module (EEC) Power Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Specifications Oil Pressure Switch (For Fuel Pump): Specifications Oil Pressure Switch 12-16 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Specifications > Page 5287 Oil Pressure Switch (For Fuel Pump): Testing and Inspection To avoid potential misdiagnosis and the unnecessary replacement of components, it is recommended that diagnosis and testing begin with Diagnostic Routines (Diagnosis by Symptom) at the Powertrain Management level. The Diagnostic Routines will lead the technician through the logical and methodical testing of a "specific" subsystem and it's related wiring and components. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Specifications > Page 5288 Oil Pressure Switch (For Fuel Pump): Service and Repair REMOVAL 1. Disconnect the oil pressure switch electrical connector. 2. Remove the oil pressure switch from the oil filter adapter. INSTALLATION 1. To install, reverse the removal procedure. 2. Check the oil level and fill to specification with Ford Premium SAE 1OW-30 Motor Oil XO-1OW-30-BSP, DSP, QSP or equivalent meeting Ford specification ESE-M2C153-E. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 5293 Power Distribution Box The Fuel Pump Relay is located in the LH front of engine compartment, in the Power Distribution box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5297 Power Distribution Box The Powertrain Control Module (EEC) Power Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 5307 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 5308 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 5314 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 5315 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement Air Flow Meter/Sensor: All Technical Service Bulletins Mass Air Flow Sensor - Assembly Replacement Article No. 96-22-5 10/21/96 MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP FORD: 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR, EXPLORER, RANGER 1993-97 VILLAGER 1994-96 BRONCO 1994-97 ECONOLINE 1995-97 F-150, WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: The Mass Air Flow (MAF) sensor is not designed to be removed from its body (die-cast or plastic) for servicing. The sensing elements located inside the by-pass tube can be damaged by poking/probing/touching. ACTION: Service the MAF sensor as an assembly (refer to Figure 1). WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement > Page 5320 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement Air Flow Meter/Sensor: All Technical Service Bulletins Mass Air Flow Sensor - Assembly Replacement Article No. 96-22-5 10/21/96 MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP FORD: 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR, EXPLORER, RANGER 1993-97 VILLAGER 1994-96 BRONCO 1994-97 ECONOLINE 1995-97 F-150, WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: The Mass Air Flow (MAF) sensor is not designed to be removed from its body (die-cast or plastic) for servicing. The sensing elements located inside the by-pass tube can be damaged by poking/probing/touching. ACTION: Service the MAF sensor as an assembly (refer to Figure 1). WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement > Page 5326 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 5327 Air Flow Meter/Sensor: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 5328 RH Component The Mass Air Flow Sensor is located in air cleaner assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 5329 Air Flow Meter/Sensor: Description and Operation PURPOSE The Mass Air Flow (MAF) sensor: - Sends the PCM a signal indicating mass airflow rate of air entering the engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal Air Flow Meter/Sensor: Service and Repair Removal REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Open the engine air cleaner. - Disconnect the Mass Air Flow (MAF) sensor connector from the wiring harness. - Release the air cleaner clamp. Separate the inlet side of the air cleaner from the outlet side of the air cleaner. 3. Cut the tape on the wire loom of the extension harness. CAUTION: Do not cut the MAF sensor wires when cutting the tape on the wire loom. - Peel back the wire loom from the extension harness near the grommet in the air cleaner. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal > Page 5332 4. Remove the grommet from the outlet side of the air cleaner and slide the grommet down the extension harness. 5. Remove the MAF sensor plate and MAF sensor from the outlet side of the engine air cleaner. 6. Disconnect the MAF sensor electrical connector. 7. Remove the nuts and separate the MAF plate from the MAF sensor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal > Page 5333 Air Flow Meter/Sensor: Service and Repair Installation INSTALLATION CAUTION: - Do not tamper with the MAF sensing elements located in the airflow bypass; tampering may result in unit failure. - The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. NOTE: - Use the alignment notch to properly align the inlet side and the outlet side of the engine air cleaner. - The MAF sensor module and body are calibrated and replaced as a unit. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations Inertia Fuel Shutoff Switch: Locations The inertia fuel shutoff switch is located under the RH cowl side trim (kick) panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 5337 Inertia Fuel Shutoff Switch: Service Precautions WARNING: Do not reset the Inertia Fuel Shutoff switch (IFS) switch until the complete fuel system has been inspected for leaks. Damage to the vehicle or personal injury may occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 5338 Inertia Fuel Shutoff Switch: Description and Operation Typical Inertia Fuel Shut-Off Switch Description The inertia fuel shutoff switch: - is used in conjunction with an electric fuel pump. - shuts off the fuel pump in the event of a collision. - consists of a steel ball held in place by a magnet. Operation When a sharp impact occurs: - the ball breaks loose from the magnet, rolls up a ramp and strikes a target plate which opens the electrical contacts of the inertia fuel shutoff switch and shuts off the fuel pump. - Once the inertia fuel shutoff switch is open, the inertia fuel shutoff switch must be manually reset before restarting the vehicle. If a collision occurs: - the electrical contacts in the inertia fuel shutoff switch open. - the fuel pump automatically shuts off, even if the engine does not stop running. - the engine will stop a few seconds after the fuel pump stops. - it is impossible to restart engine until the inertia fuel shutoff switch, located on the LH side lower back panel in the luggage compartment, is manually reset. NOTE:In the reset position, the button can be pressed an additional 1.59 mm (0.0625 inch) against a spring. This is a normal condition. WARNING: Do not reset the inertia fuel shutoff switch until the complete fuel system has been inspected for leaks or damage to vehicle or personal injury may occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 5339 Inertia Fuel Shutoff Switch: Testing and Inspection To avoid potential misdiagnosis and the unnecessary replacement of components, it is recommended that diagnosis and testing begin with Diagnostic Routines (Diagnosis by Symptom) at the Powertrain Management level. The Diagnostic Routines will lead the technician through the logical and methodical testing of a "specific" subsystem and it's related wiring and components. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 5340 Inertia Fuel Shutoff Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Remove the RH cowl side trim panel. 3. Disconnect the inertia fuel shutoff switch electrical connector. 4. Remove the inertia fuel shutoff switch. 1 Remove inertia switch bolts. 2 Remove the inertia fuel shutoff switch. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 5341 To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Specifications Oil Pressure Switch (For Fuel Pump): Specifications Oil Pressure Switch 12-16 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Specifications > Page 5345 Oil Pressure Switch (For Fuel Pump): Testing and Inspection To avoid potential misdiagnosis and the unnecessary replacement of components, it is recommended that diagnosis and testing begin with Diagnostic Routines (Diagnosis by Symptom) at the Powertrain Management level. The Diagnostic Routines will lead the technician through the logical and methodical testing of a "specific" subsystem and it's related wiring and components. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Specifications > Page 5346 Oil Pressure Switch (For Fuel Pump): Service and Repair REMOVAL 1. Disconnect the oil pressure switch electrical connector. 2. Remove the oil pressure switch from the oil filter adapter. INSTALLATION 1. To install, reverse the removal procedure. 2. Check the oil level and fill to specification with Ford Premium SAE 1OW-30 Motor Oil XO-1OW-30-BSP, DSP, QSP or equivalent meeting Ford specification ESE-M2C153-E. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Retaining Screws 2.8-3.4 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 5350 Throttle Position Sensor: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 5351 The Throttle Position Sensor is attached to the throttle body. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 5352 Throttle Position Sensor: Description and Operation PURPOSE The Throttle Position Sensor (TP): - Sends the PCM a signal indicating the throttle plate angle. - Is the main input to the PCM from the driver. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 5353 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Remove the accelerator control splash shield. 1 Remove three accelerator splash shield bolts. 2 Remove the accelerator control splash shield from the vehicle. 3. Remove the Throttle Position (TP) sensor. 1 Disconnect the electrical connector. 2 Remove the two bolts. 3 Remove the TP sensor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 5354 To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 02-19-3 > Sep > 02 > Emissions - High Idle Speeds/Throttle Sticking Throttle Body: Customer Interest Emissions - High Idle Speeds/Throttle Sticking Article No. 02-19-3 09/30/02 ^ DRIVEABILITY - IDLE - HIGH IDLE SPEEDS - THROTTLE STICKS AFTER STEADY STATE DRIVING IN EXTREME COLD AMBIENT TEMPERATURES - VEHICLES BUILT THROUGH 12/31/01 EQUIPPED WITH 4.6L ENGINE ^ 4.6L - IDLE - HIGH IDLE SPEEDS - THROTTLE STICKS AFTER STEADY STATE DRIVING IN EXTREME COLD AMBIENT TEMPERATURES - VEHICLES BUILT THROUGH 12/31/01 EQUIPPED WITH 4.6L ENGINE FORD: 1997-1999 F-250 LD 1997-2002 EXPEDITION, F-150 ISSUE In rare instances, throttle sticking may occur on a few vehicles in very cold ambient temperatures after operating at steady speed or extended idle for a period of time. This may be due to ice build-up from moisture in the PCV gas on the throttle plate or throttle body. ACTION Verify the condition is not caused by throttle body sludging, throttle cable binding, or interference between an improperly positioned floor mat and accelerator pedal. If no other conditions are identified, check for evidence of PCV system backflow. Refer to the following Service Procedure for details. SERVICE PROCEDURE Inspect the inside of the clean air tube at the PCV closure hose connection for presence of moisture, oil, or oily stains. If evidence of PCV system backflow is found, replace the PCV system with the PCV Service Kit 1L3Z-6A603-AA. Refer to the Instruction Sheet within the PCV Service Kit for Service Procedure. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 021903A Replace PCV System with 1.5 Hrs. PCV Service Kit: 1997-2002 F-150, Expedition 1997-1999 F-250 LD DEALER CODING CONDITION BASIC PART NO. CODE 6C324 42 OASIS CODES: 401000, 402000, 404000, 499000, 617400, 619400 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 98-21-10 > Oct > 98 > Engine - High Idle Speeds/Throttle Sticks Throttle Body: Customer Interest Engine - High Idle Speeds/Throttle Sticks Article No. 98-21-10 10/26/98 IDLE - HIGH IDLE SPEEDS - THROTTLE STICKS AFTER STEADY STATE DRIVING IN COLD AMBIENT TEMPERATURES - VEHICLES BUILT THROUGH 12/1/97 EQUIPPED WITH 4.6L ENGINE LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD ISSUE The vehicles identified in this TSB article should be equipped with an insulated PCV tube that was installed in production or under Recall 96S59. This insulation provides protection from PCV backflow due to ice in the PCV system created during steady speed driving in extremely cold weather. In those extreme cases where the insulated PCV tube does not completely eliminate throttle body icing due to PCV backflow, a service kit has been developed that will make these vehicles even less susceptible to PCV freezing. ACTION Verify that the condition is not caused by throttle body sludging, throttle cable binding, or interference between an improperly positioned floor mat and accelerator pedal. If no other conditions are identified, replace the PCV hose and throttle body adapter provided with the appropriate service kit. Refer to the Instruction Sheet included in the kit for installation details. PART NUMBER PART NAME F85Z-6A603-CB Service Kit - 4.6L Romeo Engine F85Z-6A603-AB Service Kit - 4.6L Windsor Engine OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 982110A Install Service kit 1.1 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 9E926 42 OASIS CODES: 404000, 610000, 610600, 612000, 612600, 617400, 619400 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 02-19-3 > Sep > 02 > Emissions - High Idle Speeds/Throttle Sticking Throttle Body: All Technical Service Bulletins Emissions - High Idle Speeds/Throttle Sticking Article No. 02-19-3 09/30/02 ^ DRIVEABILITY - IDLE - HIGH IDLE SPEEDS - THROTTLE STICKS AFTER STEADY STATE DRIVING IN EXTREME COLD AMBIENT TEMPERATURES - VEHICLES BUILT THROUGH 12/31/01 EQUIPPED WITH 4.6L ENGINE ^ 4.6L - IDLE - HIGH IDLE SPEEDS - THROTTLE STICKS AFTER STEADY STATE DRIVING IN EXTREME COLD AMBIENT TEMPERATURES - VEHICLES BUILT THROUGH 12/31/01 EQUIPPED WITH 4.6L ENGINE FORD: 1997-1999 F-250 LD 1997-2002 EXPEDITION, F-150 ISSUE In rare instances, throttle sticking may occur on a few vehicles in very cold ambient temperatures after operating at steady speed or extended idle for a period of time. This may be due to ice build-up from moisture in the PCV gas on the throttle plate or throttle body. ACTION Verify the condition is not caused by throttle body sludging, throttle cable binding, or interference between an improperly positioned floor mat and accelerator pedal. If no other conditions are identified, check for evidence of PCV system backflow. Refer to the following Service Procedure for details. SERVICE PROCEDURE Inspect the inside of the clean air tube at the PCV closure hose connection for presence of moisture, oil, or oily stains. If evidence of PCV system backflow is found, replace the PCV system with the PCV Service Kit 1L3Z-6A603-AA. Refer to the Instruction Sheet within the PCV Service Kit for Service Procedure. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 021903A Replace PCV System with 1.5 Hrs. PCV Service Kit: 1997-2002 F-150, Expedition 1997-1999 F-250 LD DEALER CODING CONDITION BASIC PART NO. CODE 6C324 42 OASIS CODES: 401000, 402000, 404000, 499000, 617400, 619400 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 98-21-10 > Oct > 98 > Engine - High Idle Speeds/Throttle Sticks Throttle Body: All Technical Service Bulletins Engine - High Idle Speeds/Throttle Sticks Article No. 98-21-10 10/26/98 IDLE - HIGH IDLE SPEEDS - THROTTLE STICKS AFTER STEADY STATE DRIVING IN COLD AMBIENT TEMPERATURES - VEHICLES BUILT THROUGH 12/1/97 EQUIPPED WITH 4.6L ENGINE LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD ISSUE The vehicles identified in this TSB article should be equipped with an insulated PCV tube that was installed in production or under Recall 96S59. This insulation provides protection from PCV backflow due to ice in the PCV system created during steady speed driving in extremely cold weather. In those extreme cases where the insulated PCV tube does not completely eliminate throttle body icing due to PCV backflow, a service kit has been developed that will make these vehicles even less susceptible to PCV freezing. ACTION Verify that the condition is not caused by throttle body sludging, throttle cable binding, or interference between an improperly positioned floor mat and accelerator pedal. If no other conditions are identified, replace the PCV hose and throttle body adapter provided with the appropriate service kit. Refer to the Instruction Sheet included in the kit for installation details. PART NUMBER PART NAME F85Z-6A603-CB Service Kit - 4.6L Romeo Engine F85Z-6A603-AB Service Kit - 4.6L Windsor Engine OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 982110A Install Service kit 1.1 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 9E926 42 OASIS CODES: 404000, 610000, 610600, 612000, 612600, 617400, 619400 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Page 5376 Throttle Body: Specifications Throttle Body Bolts 8-10 Nm Splash Shield Bolts 5.9-8.1 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service Precautions > Customer Safety Information Throttle Body: Customer Safety Information WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. Fuel in the fuel system remains under high pressure even when the engine is not running. - Before working on or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved. - The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service Precautions > Customer Safety Information > Page 5379 Throttle Body: Technician Safety Information WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. Fuel in the fuel system remains under high pressure even when the engine is not running. - Before working on or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved. - The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service Precautions > Customer Safety Information > Page 5380 Throttle Body: Vehicle Damage Warnings WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. Fuel in the fuel system remains under high pressure even when the engine is not running. - Before working on or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved. - The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service Precautions > Page 5381 Throttle Body: Description and Operation Purpose The throttle body controls airflow to the engine through a butterfly-type valve. The throttle position is controlled by an accelerator cable, attached to a pedal. Other features of the throttle body include: - A preset stop to locate the Wide-Open Throttle (WOT) position. - A throttle body-mounted Throttle Position Sensor (TPS). - A sludge-resistant coating applied to the downstream side of the throttle plate and bore area to reduce the plate-to-bore leakage. The coating should NOT be removed or cleaned. - The plate position at idle is set by the throttle return control screw contacting the throttle lever arm. Do NOT adjust/tamper with this screw unless instructed to do so. Construction The throttle body is a single-piece die casting made of aluminum. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service Precautions > Page 5382 Throttle Body: Adjustments The throttle body is NOT adjustable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service Precautions > Page 5383 Throttle Body: Service and Repair REMOVAL CAUTION: Throttle body bore and plate area have a special coating and cannot be cleaned. 1. Remove the accelerator control splash shield. 1 Remove the three accelerator control splash shield bolts. 2 Remove the accelerator control splash shield. 2. Remove the air cleaner outlet tube from the throttle body. 3. Disconnect the Throttle Position (TP) sensor electrical connector. 4. Disconnect the (A) accelerator cable and the (B) speed control actuator cable. 5. Remove the throttle body. 1 Remove the four throttle body bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service Precautions > Page 5384 2 Remove the (A) throttle body and the (B) throttle body gasket. Discard the throttle body gasket. INSTALLATION To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications Throttle Cable/Linkage: Specifications Torque Values Torque Values Accelerator Control Splash Shield Bolts 5.2-8.1 Nm Accelerator Cable Bracket Bolt and Nut 8-11 Nm Accelerator Cable to Cable Bracket Bolt 2.1-2.9 Nm Accelerator Cable to Bulkhead Bolts 2.3-3.3 Nm Accelerator Cable Bracket Bolt to Speed Control Actuator 5.9-8.1 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications > Page 5388 Throttle Cable/Linkage: Service Precautions WARNING: - The accelerator pedal and shaft should travel smoothly from the idle to wide-open throttle positions. - Hesitation on return and/or prevention of return to the idle position MUST NOT occur. - Surrounding components such as wiring, hoses, sound insulator and floor covering MUST NOT contact the sliding inner member of the accelerator cable or the accelerator pedal and shaft. - The sliding inner member of the accelerator cable should NOT be lubricated and is not serviceable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications > Page 5389 Throttle Cable/Linkage: Description and Operation OPERATION The throttle angle is controlled by an accelerator cable, and an accelerator pedal and shaft. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications > Page 5390 Throttle Cable/Linkage: Testing and Inspection INSPECTION AND VERIFICATION - Inspect the accelerator pedal and shaft and attaching linkage for damage or distortion which would bind or limit accelerator travel. - Inspect the accelerator cable for kinks or fraying which may cause binding. - Inspect the engine idle speed adjustment to ensure correct idle speed specification after any accelerator linkage adjustment or repair. NOTE: Care should be exercised when performing service on or around the accelerator pedal linkage and controls: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications > Page 5391 Throttle Cable/Linkage: Adjustments The accelerator pedal, shaft, cable, and linkage components are non-adjustable, and can be serviced by replacement only. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications > Page 5392 Throttle Cable/Linkage: Service and Repair REMOVAL 1. Disconnect the (A) accelerator cable from the (B) accelerator pedal and shaft. 2. Remove the accelerator control splash shield. 1 Remove the accelerator control splash shield bolts. 2 Remove the accelerator control splash shield. 3. Unclip the accelerator cable from the accelerator cable clip. 4. Remove the (A) accelerator cable to bulkhead bolts and pull the (B) accelerator cable through the bulkhead. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications > Page 5393 5. Remove the snap-in-end fitting of the accelerator cable from the accelerator cable bracket. 6. Disconnect the accelerator cable from the throttle body cam. 1 Roll the throttle body cam forward. 2 Slide the accelerator cable end from the throttle body cam. INSTALLATION To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Retaining Screws 2.8-3.4 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 5397 Throttle Position Sensor: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 5398 The Throttle Position Sensor is attached to the throttle body. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 5399 Throttle Position Sensor: Description and Operation PURPOSE The Throttle Position Sensor (TP): - Sends the PCM a signal indicating the throttle plate angle. - Is the main input to the PCM from the driver. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 5400 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Remove the accelerator control splash shield. 1 Remove three accelerator splash shield bolts. 2 Remove the accelerator control splash shield from the vehicle. 3. Remove the Throttle Position (TP) sensor. 1 Disconnect the electrical connector. 2 Remove the two bolts. 3 Remove the TP sensor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 5401 To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > System Information > Diagrams > Diagram Information and Instructions Variable Induction System: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > System Information > Diagrams > Diagram Information and Instructions > Page 5406 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > System Information > Diagrams > Diagram Information and Instructions > Page 5407 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > System Information > Diagrams > Diagram Information and Instructions > Page 5408 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > System Information > Diagrams > Diagram Information and Instructions > Page 5409 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > System Information > Diagrams > Diagram Information and Instructions > Page 5410 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > System Information > Diagrams > Diagram Information and Instructions > Page 5411 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > System Information > Diagrams > Diagram Information and Instructions > Page 5412 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > System Information > Diagrams > Diagram Information and Instructions > Page 5413 Variable Induction System: Connector Views Connector: C118 is at the Intake Manifold Control Solenoid. There is no connector view for C118 given. Refer to the wiring diagram. There is an inline connector shared between this solenoid, the EGR Vacuum Regulator (EVR) solenoid, the Idle Air Control (IAC) and the fuel injectors. In-Line Connector Faces - C120 Connector: C120, Color = 'Black', Terminal= '42' Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > System Information > Diagrams > Page 5414 Variable Induction System: Description and Operation PURPOSE The Intake Manifold Tuning (IMT) valve assembly increases mid-range torque of the engine. CONFIGURATION The IMT valve is a single valve that blends the air flow of a dual plenum type intake manifold. The IMT Valve assembly is a two-position valve located in the intake manifold. The MT Valve is normally closed at low engine speeds and provides torque improvements by separating intake pulses of a dual plenum system. Intake Manifold Tuning Valve (IMTV) OPERATION - The PCM uses the Throttle Position (TP) sensor and rpm input signals to determine activation of the Intake Manifold Tuning Valve system. Below approximately 3000 rpm, the IMT valve shutter is closed, and above approximately 3000 rpm, the shutter is opened. There must be a positive change in voltage from the TP sensor along with the increase in rpm to open the shutter. - The PCM uses the information from the input signals to control the IMT valve based upon rpm and changes in throttle position. - When commanded on by the PCM, the valve opens up the end of the vertical separating wall at high speeds to allow both sides of the manifold to blend together to provide air flow tuning on the dual plenum system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Firing Order: Specifications The RH (Passenger's) side ................................................................................................................. ................................................ Cylinders 1, 2, 3, and 4 The LH (Driver's side) .......................................................................................................................... ............................................. Cylinders 5, 6, 7 and 8 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Page 5419 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Page 5420 Firing Order 1-3-7-2-6-5-4-8 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Firing Order Firing Order: 1-3-7-2-6-5-4-8 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Timing Marks and Indicators > System Information > Locations Timing Marks and Indicators: Locations The timing marks are located on the crankshaft pulley/damper. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt 8-12 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 5431 Camshaft Position Sensor: Locations Engine View The Camshaft Position Sensor is located in front of the engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 5432 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 5433 Camshaft Position Sensor: Description and Operation The Camshaft Position (CMP) sensor: - Sends the PCM a signal indicating camshaft position, which is used for fuel synchronization. NOTE: The Camshaft Position (CMP) sensor is also referred to as Cylinder Identification Sensor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 5434 Camshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the CMP sensor. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Retainer Torque 8-12 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 5438 Crankshaft Position Sensor: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 5439 The Crankshaft Position Sensor is located at the lower front of engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 5440 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) sensor: - Sends the PCM a signal indicating crankshaft position. - Is essential for calculating spark timing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 5441 Crankshaft Position Sensor: Service and Repair REMOVAL WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 3. Release the tension on the accessory drive belt. 1. Remove the A/C compressor. 1 Remove the A/C compressor bolts. 2 Remove the A/C compressor and position aside. NOTE: Do not remove lines from the A/C compressor. 5. Remove the (A) CKP sensor bolt and the (B) CKP sensor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 5442 To install, reverse the removal procedure NOTE:If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Secondary Suppression Resistor, Ignition > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips Ignition Coil: Technical Service Bulletins Ignition System - Coil-On-Plug Misfire Diagnostic Tips TSB 05-22-8 11/14/05 WDS COP KIT DIAGNOSTIC TIPS - COIL ON PLUG (COP) IGNITION SYSTEMS - ENGINE MISFIRE OR ROUGH RUNNING FORD: 1996-1999 Taurus SHO 1998-2006 Crown Victoria, Mustang 2000 Taurus 2002-2005 Thunderbird 2003-2006 Focus 2004-2006 Taurus 2005-2006 Five Hundred, Freestyle 1997-2006 E-Series, Expedition, F-150 1999-2006 F-Super Duty 2000-2005 Excursion, F-53 2001-2006 Escape 2002-2005 Explorer 2005-2006 Escape Hybrid LINCOLN: 1997-1998 Mark VIII 1998-2002 Continental 1998-2006 Town Car 2000-2006 LS 1998-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator MERCURY: 1998-2006 Grand Marquis 2000 Sable 2004-2005 Sable 2005-2006 Montego 2002-2005 Mountaineer 2005-2006 Mariner 2006 Mariner Hybrid This article supersedes TSB 04-16-01 to update the vehicle applications and model years. NOTE FOLLOW THIS TSB PROCEDURE ONLY IF THERE ARE NO SPECIFIC MISFIRE TSBs/SSMs RELEASED FOR THE VEHICLE SYMPTOM BEING EXPERIENCED. ISSUE Approximately 50% of coil on plug (COP) coils returned for warranty do not have a problem. ACTION The misfiring cylinder must be identified through Self-Test misfire codes or through WDS Power Balance. Rule out base engine problems, rule out fuel problems, and then look at ignition problems (be sure to rule out coil primary circuit issues). Once the above steps have been completed, and the issue is in the secondary part of the ignition system, the oscilloscope procedure outlined in this TSB can isolate the difference between a coil or spark plug problem. SERVICE PROCEDURE The optional WDS COP Kit available through Rotunda will provide more accurate diagnosis and help reduce replacement of non-defective parts. The Kit (418-F5528) can be purchased through 1-800-ROTUNDA. The following material will detail the diagnostic steps on WDS to take the guesswork out of misfire diagnosis using the COP Kit. The following procedure is for cylinder specific misfires and not random misfires. Random misfires have a different root cause and are not covered by this TSB. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 5451 Misfire Definition: A misfiring cylinder is lacking power relative to the other cylinders. The causes for a cylinder specific misfire could be fuel, spark, or mechanical problems. Perform a thorough visual inspection. If no visible concerns are found use the following WDS tools for misfire diagnosis: ^ Self-test (Check for codes first) Power Balance (Identify the cylinder of concern) ^ Relative Compression (Rule out a possible mechanical issue) ^ Fuel (Make sure fuel injectors are not restricted) ^ Ignition (Make sure spark plugs and coils are working properly) ^ Oscilloscope (Detailed signal analysis) NOTE USE THE ENCYCLOPEDIA BUTTON IN THE LOWER LEFT CORNER OF THE SCREEN FOR DETAILED INFORMATION ON THE WDS TOOL BEING DISPLAYED. If there is a self-test code identifying a particular cylinder then you just need to determine if it is a fuel, ignition, or possibly a mechanical problem. Proceed to Step 2 after running Relative Compression to rule out any mechanical issues. If there is no self-test code and the customer concern is a miss, proceed to Step 1. Step 1: (Select Toolbox Icon, then Powertrain, then Power Balance) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 5452 The cylinder specific miss has to be identified as shown in the example in Figure 2 in order to proceed with the remaining steps. If the miss does not occur at idle (in the bay), try to brake torque the engine. This extra loading should reproduce the miss in the bay. If the miss cannot be reproduced during brake torque, select Relative Compression under Powertrain on WDS before going on a road test to rule out mechanical problems. If Relative Compression shows a problem then the base engine issue must be serviced. If Relative Compression results are good (Figure 3), road test under as many different driving conditions as possible until the miss occurs on Power Balance. Some misses may be very intermiffent so be patient and concentrate on steady load conditions. Once a cylinder dropout is identified proceed to Step 2. Step 2: (Select Toolbox Icon, then Powertrain, then Fuel System Test) Run Fuel System Test on WDS to determine if there may be a fuel problem. After completing fuel Pressure/Leakdown test, select Injector flow to isolate Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 5453 a restricted injector as shown in Figure 4. If all the injectors are within specification, proceed to Step 3. Step 3: (Select Toolbox Icon, then Powertrain, then Ignition System Test) Run Ignition System Test on WDS to determine if there is an ignition problem. Look at both duration (DUR) and kilovolts (KV) and look for values that standout from the rest as shown in Figure 5 and Figure 6. NOTE LIVE DISPLAY HAS TO AVERAGE IGNITION VALUES BECAUSE THERE IS TOO MUCH DATA TO DISPLAY. MAKE A CAPTURE TO VIEW EACH ENGINE EVENT WITHOUT AVERAGING. THIS CAN BE HELPFUL WHEN THE PROBLEM IS INTERMITTENT. IF THE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 5454 MISS IS EXTREMELY INTERMITTENT AND DOES NOT SHOW UP IN IGNITION, PROCEED TO STEP 4. If either spark duration or peak KV on the Red Probe (Suspect Cylinder) are offset from the values displayed on the Black Probe (Known Good Cylinder) then the problem is in the ignition system. Rule out coil primary circuit issues before proceeding to coil secondary issues such as the spark plug , coil boot, or possibly the coil. Use the WDS Oscilloscope with the COP kit to determine if the issue is the coil or the spark plug. Step 4: (Select Toolbox, then Oscilloscope) WARNING SECONDARY IGNITION VOLTAGES ARE VERY HIGH. KEEP HANDS AND TOOLS AWAY FROM THE END OF THE COIL THAT SUPPLIES THE SPARK. SET-UP: With the engine off, pull the suspect coil from the cylinder well and turn it upside down so the coil cannot spark to any other surface as shown in Figure 1. Wrap a clean shop cloth around the hard shell of the coil to help keep the coil propped up and stable. CAUTION THE COIL BOOT CAN BE DAMAGED IF THE COIL SPARKS TO ANOTHER SURFACE DURING THIS PROCEDURE. Keep the coil connected to the harness and leave the WDS COP clip attached to the coil. Route the coil clip wire and cable away from the coil being tested as well as other coils to avoid noise interference. Disconnect the injector of the cylinder being tested so raw fuel is not washing the cylinder. This is a stress test for the coil. The type of waveform displayed on the oscilloscope will show whether a coil or the plug is the problem if all previous steps have been followed. Keep hands and tools away from the end of the coil that supplies the spark. COP Stress Test Procedure: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 5455 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 5456 Go to the Oscilloscope Tool and select Channel 3, then select Auto, then select COP_STRESS_TEST_RED. This pre-configured setting will zoom-in on the peak firing of the coil being tested. Start the engine and be sure the coil is not sparking to any surface. If the coil is sparking to other surfaces, turn the engine off immediately and readjust the coil so it cannot spark to any other surface. Restart the engine and touch the Red Man icon to start the oscilloscope. All settings are pre-configured and no adjustments are necessary. Compare the waveform you get with the examples provided in Figures 7, 8, and 9). Figure 7 is a good waveform. If your waveform is similar to Figure 7 the coil is working correctly. Suspect the spark plug. Figure 8 and Figure 9 are examples of problem coils. Replace the coil if the waveform is similar to Figures 8 or 9. The coil is causing the misfire when the peak firing appears like those shown in Figures 8 and 9. Notice the difference in the peak-firing signal when compared to the good peak signal in Figure 7. Figure 9 shows a more dramatic fault in the peak failure. Most root causes of misfire issues can be identified quickly using the steps outlined above. Some misfire issues can be difficult making the oscilloscope an important part of your diagnostic toolbox. OTHER APPLICABLE ARTICLES: 05-13-4 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Page 5457 Ignition Coil: Specifications Ignition Coil and Bracket Bolts, LH and RH ................................................................................................................................... 20-30 Nm (15-22 Lb/Ft) Ignition Coil and Bracket Nut, LH ................................................................................................................................................... 20-30 Nm (15-22 Lb/Ft) Ignition Coil Bolts .................................................................................................... ............................................................................ 5-7 Nm (44-62 Lb/In) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Connector Views Ignition Coil: Connector Views Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Connector Views > Page 5460 Ignition Coil: Mechanical Diagrams The RH (Passenger's) side ................................................................................................................. ................................................ Cylinders 1, 2, 3, and 4 The LH (Driver's side) .......................................................................................................................... ............................................. Cylinders 5, 6, 7 and 8 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Connector Views > Page 5461 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Connector Views > Page 5462 Firing Order 1-3-7-2-6-5-4-8 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 5463 Ignition Coil: Description and Operation NOTE: The following image is a generic image and may not apply to your vehicle. PURPOSE The Electronic Ignition-High Data Rate System (EI) coils provide high voltage needed to jump the gap of the spark plugs and ignite the air/fuel mixture. CONSTRUCTION The coil pack contains multiple coils. Each coil within a coil pack contains a primary and secondary circuit. Primary Windings The windings in the primary circuit is wound on a silicon steel core bobbin. The primary circuit grounds use the same ground through the DIS module. Secondary Windings The winding in the secondary circuit is on a segmented bobbin. The secondary winding uses smaller gauge wire and more turns than the primary circuit. The secondary high tension towers are connected in pairs. OPERATION The ignition coil fires two spark plugs simultaneously, one on the compression stroke and one on the exhaust stroke. Effective Spark When a piston is on compression stroke, most of the ignition coil's available current jumps the gap of the spark plug firing from the center electrode to side electrode, because the resistance is low. Wasted Spark When the companion piston is on exhaust stroke, the spark is wasted. Very little coil energy is wasted. The companion plug fires from the side electrode to the center electrode. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service and Repair > Ignition Coil Pack Ignition Coil: Service and Repair Ignition Coil Pack Removal REMOVAL NOTE:Procedure is for either RH or LH ignition coil; RH ignition coil is shown. 1. Disconnect the ignition coil electrical connections. 1 Disconnect the ignition coil electrical connector. 2 Disconnect the radio capacitor electrical connector. 2. Squeeze the (A) locking tabs and disconnect the (B) spark plug wires (four each side). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service and Repair > Ignition Coil Pack > Page 5466 NOTE: Spark plug wires must be connected to the proper ignition coil terminal. Mark spark plug wire locations. 3. Remove the ignition coil. 1 Remove the ignition coil bolts. 2 Remove the ignition coil. 4. Inspect the ignition coil for carbon tracks or damage. Installation INSTALLATION NOTE:Procedure is for either LH or RH ignition coil; RH ignition coil is shown. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service and Repair > Ignition Coil Pack > Page 5467 1. Install the ignition coil. 1 Position the ignition coil. 2 Install the ignition coil bolts. 2. Connect the ignition coil electrical connections. 1 Connect the ignition coil electrical connector. 2 Connect the radio capacitor electrical connector. 3. Squeeze the (A) locking tabs and connect the (B) spark plug wires (four each side). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service and Repair > Ignition Coil Pack > Page 5468 CAUTION: Spark plug wires must be connected to the proper ignition coil terminal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service and Repair > Ignition Coil Pack > Page 5469 Ignition Coil: Service and Repair Ignition Coil Bracket REMOVAL 1. Remove the ignition coils. 2. Remove the RH ignition coil bracket. 1 Remove the RH ignition coil bracket bolts. 2 Remove the RH ignition coil bracket. 3. Remove the power steering hose bracket. 1 Remove the nuts. 2 Remove the power steering hose bracket. 4. Remove the LH ignition coil bracket. 1 Disconnect the Camshaft Position (CMP) sensor electrical connector. 2 Remove the LH ignition coil bracket bolt. 3 Remove the LH ignition coil bracket. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service and Repair > Ignition Coil Pack > Page 5470 1. Install the RH ignition coil bracket. 1 Position the RH ignition coil bracket. 2 Install the RH ignition coil bracket bolts. 2. Install the LH ignition coil bracket. 1 Position the LH ignition coil bracket. 2 Install the bolt. 3 Connect the CMP sensor electrical connector. 3. Install the power steering hose bracket. 1 Position the power steering hose bracket. 2 Install the nuts. 4. Install the ignition coils. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations Ignition Control Module: Locations The ignition control module is integrated within the powertrain control module. It is not a separately replaceable component. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Page 5474 Ignition Control Module: Description and Operation PURPOSE - The Ignition Control Module (ICM) is incorporated within the Powertrain Control Module (PCM). The ICM receives engine position and speed information from within the crankshaft position sensor and desired spark advance information from the PCM. OPERATION - The ICM synthesizes a profile ignition pick up signal and ignition diagnostic monitor signal for use within The PCM. - The PCM uses this information to determine which ignition coil to fire, calculating the turn ON/OFF times of the ignition coil required to achieve the correct dwell and spark advance. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor 20-27 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications > Page 5478 Knock Sensor: Description and Operation The knock sensor is located in the lifter valley and: - Sends a signal to the PCM indicating engine detonation. - If detonation is occurring, the PCM then changes engine timing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications > Page 5479 Knock Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the Knock Sensor (KS) . 1 Disconnect the electrical connector. 2 Remove the KS. INSTALLATION 1. Install the Knock Sensor (KS) 1 Install the KS. 2 Connect the electrical connector. 2. Install the intake manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations Ignition Control Module: Locations The ignition control module is integrated within the powertrain control module. It is not a separately replaceable component. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 5484 Ignition Control Module: Description and Operation PURPOSE - The Ignition Control Module (ICM) is incorporated within the Powertrain Control Module (PCM). The ICM receives engine position and speed information from within the crankshaft position sensor and desired spark advance information from the PCM. OPERATION - The ICM synthesizes a profile ignition pick up signal and ignition diagnostic monitor signal for use within The PCM. - The PCM uses this information to determine which ignition coil to fire, calculating the turn ON/OFF times of the ignition coil required to achieve the correct dwell and spark advance. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor Bolt 8-12 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 5489 Camshaft Position Sensor: Locations Engine View The Camshaft Position Sensor is located in front of the engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 5490 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 5491 Camshaft Position Sensor: Description and Operation The Camshaft Position (CMP) sensor: - Sends the PCM a signal indicating camshaft position, which is used for fuel synchronization. NOTE: The Camshaft Position (CMP) sensor is also referred to as Cylinder Identification Sensor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 5492 Camshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the CMP sensor. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Retainer Torque 8-12 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 5496 Crankshaft Position Sensor: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 5497 The Crankshaft Position Sensor is located at the lower front of engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 5498 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) sensor: - Sends the PCM a signal indicating crankshaft position. - Is essential for calculating spark timing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 5499 Crankshaft Position Sensor: Service and Repair REMOVAL WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 3. Release the tension on the accessory drive belt. 1. Remove the A/C compressor. 1 Remove the A/C compressor bolts. 2 Remove the A/C compressor and position aside. NOTE: Do not remove lines from the A/C compressor. 5. Remove the (A) CKP sensor bolt and the (B) CKP sensor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 5500 To install, reverse the removal procedure NOTE:If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 5506 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 5507 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 5508 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 5509 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 5510 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Ignition Switch Lock Cylinder: Service and Repair Functional REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key and turn to the RUN position. (2) Press the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. INSTALLATION 1. To install, reverse the removal procedure. - Verify ignition switch lock cylinder operation. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 5513 Ignition Switch Lock Cylinder: Service and Repair Non-Functional REMOVAL 1. Disconnect the battery ground cable. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. 4. Remove the ignition switch lock cylinder. - Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. - Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the bearing and the gear. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 5514 - Thoroughly clean all drill shavings from the steering column and inspect for damage. INSTALLATION 1. To install, reverse the removal procedure, using a new ignition switch lock cylinder. - Verify ignition switch lock cylinder operation. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor 20-27 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 5518 Knock Sensor: Description and Operation The knock sensor is located in the lifter valley and: - Sends a signal to the PCM indicating engine detonation. - If detonation is occurring, the PCM then changes engine timing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 5519 Knock Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the Knock Sensor (KS) . 1 Disconnect the electrical connector. 2 Remove the KS. INSTALLATION 1. Install the Knock Sensor (KS) 1 Install the KS. 2 Connect the electrical connector. 2. Install the intake manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 962523 > Dec > 96 > Spark Plug Wires - MIL ON/DTCs P0300 Through P0308 Set Spark Plug: Customer Interest Spark Plug Wires - MIL ON/DTCs P0300 Through P0308 Set Article No. 96-25-23 12/02/96 ^ RUNS ROUGH - MALFUNCTION INDICATOR LAMP (MIL) ON-DIAGNOSTIC TROUBLE CODES (DTCS) P0300 THROUGH P0308 STORED IN MEMORY - VEHICLES BUILT THROUGH 10/14/96 WITH 4.6L ENGINE ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ON - RUNS ROUGH - DIAGNOSTIC TROUBLE CODES (DTCS) P0300 THROUGH P0308 STORED IN MEMORY - VEHICLES BUILT THROUGH 10/14/96 WITH 4.6L ENGINE LIGHT TRUCK: 1997 ECONOLINE, EXPEDITION, F-150 ISSUE: The Malfunction Indicator Lamp (MIL) may illuminate and Diagnostic Trouble Codes (DTCs) P0300 through P0308 may be stored in memory and/or the engine may run rough. This may be caused by water intrusion into the spark plug well causing the spark to travel directly to ground instead of through the spark plug, resulting in a misfire. ACTION: Inspect the spark plugs for signs of moisture and replace the spark plugs and spark plug wires. Apply dielectric compound on all of the spark plug wire boots. The new spark plug wires and the dielectric compound should reduce the possibility of misfire if water intrusion into the spark plug well occurs. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect and remove any water that may be sitting in the spark plug wells by blowing out the water using compressed air. 2. Inspect the spark plugs for signs of "tracking." If "tracking" is present, there may be a fine, broken "pencil" line on the blue rings only and/or a thick smudgy series of continuous lines depending on how long the vehicle was operated while misfiring. These lines may feel like a crack if the fingernail is rubbed across the lines. Refer to Figure 1. 3. If "tracking" is found, replace all eight (8) of the spark plugs and torque the new Spark Plugs (AWSF-32-PP) to 16-20 N.m (12-15 lb-ft). 4. Replace all eight (8) of the Spark Plug Wires with new wires (F6PZ-12259-HC). Be sure to apply Silicone Caliper Grease and Dielectric Compound (D7AZ-19A331-A) on the inside of all spark plug wire boots. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 962523 > Dec > 96 > Spark Plug Wires - MIL ON/DTCs P0300 Through P0308 Set > Page 5528 5. Position the spark plug wire boots 90 degrees to the crankshaft centerline with the spark plug wires facing outboard. The lip of the spark plug wire boot must be flush to the manifold. Refer to Figure 2. PART NUMBER PART NAME F6PZ-12259-HC Spark Plug Wires AWSF-32-PP Spark Plug D7AZ-19A331-A Silicone caliper Grease And Dielectric Compound OTHER APPLICABLE ARTICLES: 96-20-5 960923 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 962523 > Dec > 96 > Spark Plug Wires - MIL ON/DTCs P0300 Through P0308 Set > Page 5529 OPERATION DESCRIPTION TIME 962523A Replace Spark Plugs And 1.1 Hr. Wires DEALER CODING CONDITION BASIC PART NO. CODE 12286 48 OASIS CODES: 206000, 608400, 608500, 608600, 609000, 609400, 609500, 609600, 609800, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 962523 > Dec > 96 > Spark Plug Wires - MIL ON/DTCs P0300 Through P0308 Set Spark Plug: All Technical Service Bulletins Spark Plug Wires - MIL ON/DTCs P0300 Through P0308 Set Article No. 96-25-23 12/02/96 ^ RUNS ROUGH - MALFUNCTION INDICATOR LAMP (MIL) ON-DIAGNOSTIC TROUBLE CODES (DTCS) P0300 THROUGH P0308 STORED IN MEMORY - VEHICLES BUILT THROUGH 10/14/96 WITH 4.6L ENGINE ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ON - RUNS ROUGH - DIAGNOSTIC TROUBLE CODES (DTCS) P0300 THROUGH P0308 STORED IN MEMORY - VEHICLES BUILT THROUGH 10/14/96 WITH 4.6L ENGINE LIGHT TRUCK: 1997 ECONOLINE, EXPEDITION, F-150 ISSUE: The Malfunction Indicator Lamp (MIL) may illuminate and Diagnostic Trouble Codes (DTCs) P0300 through P0308 may be stored in memory and/or the engine may run rough. This may be caused by water intrusion into the spark plug well causing the spark to travel directly to ground instead of through the spark plug, resulting in a misfire. ACTION: Inspect the spark plugs for signs of moisture and replace the spark plugs and spark plug wires. Apply dielectric compound on all of the spark plug wire boots. The new spark plug wires and the dielectric compound should reduce the possibility of misfire if water intrusion into the spark plug well occurs. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect and remove any water that may be sitting in the spark plug wells by blowing out the water using compressed air. 2. Inspect the spark plugs for signs of "tracking." If "tracking" is present, there may be a fine, broken "pencil" line on the blue rings only and/or a thick smudgy series of continuous lines depending on how long the vehicle was operated while misfiring. These lines may feel like a crack if the fingernail is rubbed across the lines. Refer to Figure 1. 3. If "tracking" is found, replace all eight (8) of the spark plugs and torque the new Spark Plugs (AWSF-32-PP) to 16-20 N.m (12-15 lb-ft). 4. Replace all eight (8) of the Spark Plug Wires with new wires (F6PZ-12259-HC). Be sure to apply Silicone Caliper Grease and Dielectric Compound (D7AZ-19A331-A) on the inside of all spark plug wire boots. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 962523 > Dec > 96 > Spark Plug Wires - MIL ON/DTCs P0300 Through P0308 Set > Page 5535 5. Position the spark plug wire boots 90 degrees to the crankshaft centerline with the spark plug wires facing outboard. The lip of the spark plug wire boot must be flush to the manifold. Refer to Figure 2. PART NUMBER PART NAME F6PZ-12259-HC Spark Plug Wires AWSF-32-PP Spark Plug D7AZ-19A331-A Silicone caliper Grease And Dielectric Compound OTHER APPLICABLE ARTICLES: 96-20-5 960923 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 962523 > Dec > 96 > Spark Plug Wires - MIL ON/DTCs P0300 Through P0308 Set > Page 5536 OPERATION DESCRIPTION TIME 962523A Replace Spark Plugs And 1.1 Hr. Wires DEALER CODING CONDITION BASIC PART NO. CODE 12286 48 OASIS CODES: 206000, 608400, 608500, 608600, 609000, 609400, 609500, 609600, 609800, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Electrode Gap 1.32-1.42 mm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Gap > Page 5539 Spark Plug: Specifications Spark Plug 9-20 Nm Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 5540 Spark Plug: Locations The Spark Plugs are located along the inboard sides of the cylinder heads, and outboard of the intake manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 5541 Spark Plug: Application and ID RH Original Spark Plug ....................................................................................................................... ........................................................ AWSF32PG (a) LH Original Spark Plug ..................................... ............................................................................................................................................. AWSF32P (a) Replacement Spark Plug (Either Side) ......................................................................................................................................................... AWSF32PP (a) (a) If a spark plug is removed for examination, it must be reinstalled in the same cylinder. If a spark plug needs to be replaced, use only spark plugs with the base part number suffix "PP" as shown on the engine decal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 5542 Spark Plug: Description and Operation Spark Plug Construction PURPOSE Ignites the combustion mixture. LOCATION Threaded into the cylinder head, at the combustion chamber. OPERATION The spark plug provides a path for the high current of the secondary circuit to flow to ground. The only paths for this current are through the ground electrode and center electrode across the spark gap. The spark produced when the current jumps the gap and ignites the air/fuel mixture in the cylinder. Spark Plug Heat Range CONSTRUCTION The temperature of the spark plug is determined by the length of the insulator and the size of the heatsink area. The longer the insulator is, the smaller the heatsink area will be and this will cause the spark plug to be hotter. - Change high voltage pulses to spark at gap which ignites fuel and air mixture. - Have a platinum enhanced active electrode for long life. FEATURES The active electrode is different for LH and RH spark plugs: - On the RH side (cylinders 1, 2, 3, and 4) are type AWSF-32PG. - On the LH side (cylinders 5, 6, 7 and 8) are type AWSF-32P. NOTE: The replacement spark plugs are AWSF-32PP; both electrodes are platinum enhanced so it can replace either a RH or LH spark plug. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 5543 Spark Plug: Testing and Inspection CLEANING AND INSPECTION Spark Plugs Inspect the electrodes and outer surface. Refer to Spark Plug Inspection Chart. Replace spark plugs if they are worn or damaged. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 5544 Spark Plug: Adjustments Gapping Spark Plug Check and set the spark plug electrode gap to: 1.32-1.41 mm (0.052-0.056 inch) using an appropriate gapping tool. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 5545 Spark Plug: Service and Repair REMOVAL NOTE: - If an original spark plug is reused, make sure it is placed in the same cylinder it was taken from. Replacement spark plugs can be used in any cylinder. - Use compressed air to remove any debris from the spark plug well before removing the spark plugs. 1. With a twisting, pulling motion disconnect the spark plug wire from the spark plug. 2. Squeeze the (A) locking tabs and disconnect the (B) spark plug wire from the (C) ignition coil. 3. Remove the RH spark plugs. 4. Remove the LH spark plugs. 5. Inspect the spark plugs for: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 5546 - Deposits bridging spark plug gap (A). - Wet black deposits (oil fouling) (B). - Dry black deposits (carbon fouling) (C). - Overheating (D). - Deposits fused on spark plug (E). Pre-ignition damage (F). - Normal spark plug (G). INSTALLATION NOTE: If an original spark plug is reused, make sure it is placed in the same cylinder it was taken from. Replacement spark plugs can be used in any cylinder. 1. Apply Silicone Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A to inside of spark plug wire boots. 2. Adjust the spark plug gap as required. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 5547 3. Install the LH spark plugs. 4. Install the RH spark plugs. 5. Connect the spark plug wires. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair Pressure Regulating Solenoid: Service and Repair REMOVAL 1. Remove the manual control lever shaft. 2. Disconnect the electronic pressure control (EPC) solenoid electrical connector. CAUTION: Do not pull on the wires. This can damage the wires or the connector and can result in transmission solenoid or sensor failure. 3. Remove the EPC solenoid. INSTALLATION 1. Install the EPC solenoid. 2. Connect the electronic pressure control (EPC) solenoid electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Page 5554 3. Install the manual control lever shaft. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications Shift Interlock Solenoid: Specifications TORQUE SPECIFICATIONS Shift Lock Actuator Bolts ...................................................................................................................................................... 7-11 Nm (62.5-98 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 5558 Shift Interlock Solenoid: Service and Repair REMOVAL 1. Remove the steering column. 2. Remove the insert plate and shift lock actuator. (1) Remove the three shift lock actuator bolts. (2) Remove the insert plate and shift lock actuator. 3. Remove the insert plate from the shift lock actuator. - Remove and discard the shift lock actuator clip. NOTE: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced in the field. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams Shift Solenoid: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications Transfer Case Actuator: Specifications TORQUE SPECIFICATIONS Shift Motor Bolts .................................................................................................................................. .................................... 8-11 Nm (71-98 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 5566 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 5567 Transfer Case Actuator: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 5568 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 5569 Transfer Case Actuator: Description and Operation The shifting operation of the front drive axle is accomplished by activating the vacuum motor from a switch located on the instrument panel. It is recommended that shifting of the front axle should be done with the front wheels in a straight ahead position and during light throttle application. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor Transfer Case Actuator: Service and Repair Transfer Case Shift Motor REMOVAL 1. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. Raise and support the vehicle. 2. Disconnect the shift motor electrical connector. 3. Remove the coil wire from the transfer case shift motor electrical connector. 1 Remove the wire connector spacer. 2 Remove the coil wire and pin. Use proper electrical connector pin remover. 4. Remove the transfer case shift motor. 1 Remove the four bolts. 2 Remove the transfer case shift motor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 5572 1. Install the transfer case shift motor. 1 Position the transfer case shift motor. 2 Install the four bolts. 2. Install the coil wire into the transfer case shift motor electrical connector. 1 Install the coil wire and pin. 2 Install the wire connector spacer. 3. Connect the electric shift motor electrical connector. 4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 5573 Transfer Case Actuator: Service and Repair Vacuum Reservoir REMOVAL 1. Remove the right front fender splash shield. 1 Remove the screws. 2 Remove the pushpins. 3 Remove the right front fender splash shield. 2. Remove the engine vacuum reservoir. 1 Remove the bolts. 2 Disconnect the vacuum harness from the engine vacuum reservoir and remove the engine vacuum reservoir. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 5574 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 5575 Transfer Case Actuator: Service and Repair Auxiliary Vacuum Reservoir REMOVAL 1. Remove the front fender splash shield. 2. Disconnect the vacuum harness from the auxiliary vacuum reservoir and the A/C vacuum reservoir. 3. Slide the vacuum reservoir assembly out of the battery tray. 4. Separate the A/C vacuum reservoir from the auxiliary vacuum reservoir. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation The transmission control switch (TCS) is a momentary contact switch. When the switch is pressed, a signal is sent to the powertrain control module (PCM) to allow automatic shifts from first through fourth gears or first through third gears only. The PCM energizes the transmission control indicator lamp (TCIL) when the switch has been pressed to cancel overdrive. The TCIL indicates overdrive cancel mode activated (lamp on) and electronic pressure control (EPC) circuit shorted (lamp flashing) or monitored sensor failure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Page 5581 Overdrive Indicator Lamp: Testing and Inspection The TCIL indicates overdrive cancel mode activated (lamp on), electronic pressure control circuit shorted or monitored sensor failure (lamp flashing). For testing procedures, Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Adjustments Shift Indicator: Adjustments 1. Remove the upper instrument panel steering column cover. 2. Place the transmission control selector lever in the OD position. - Rotate the transmission control selector lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise (a) position). 3. Hang an eight pound weight on the transmission control selector lever. 4. Center the pointer in the middle of the OD position. - Rotate the thumbwheel located on the bottom of the steering column to adjust the pointer. 5. Remove the eight pound weight. 6. Carefully move the shift control selector lever from detent to detent and compare with transmission settings. - Readjust if necessary. 7. Install the upper instrument panel steering column cover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Testing and Inspection Transmission Mode Indicator - A/T: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Testing and Inspection Four Wheel Drive Indicator Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque On Demand Relay Four Wheel Drive Selector Relay: Locations Torque On Demand Relay Instrument Panel View The Torque On Demand Relay is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque On Demand Relay > Page 5598 Four Wheel Drive Selector Relay: Locations Transfer Case Shift Relay Instrument Panel View The Transfer Case Shift Relays are located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Torque On Demand Relay Torque On Demand Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Torque On Demand Relay > Page 5601 Transfer Case Shift Relays Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > E40D Transmission Transmission Control Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > E40D Transmission > Page 5608 Transmission Control Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Page 5609 Overdrive Switch: Description and Operation The transmission control switch (TCS) is a momentary contact switch. When the switch is pressed, a signal is sent to the powertrain control module (PCM) to allow automatic shifts from first through fourth gears or first through third gears only. The PCM energizes the transmission control indicator lamp (TCIL) when the switch has been pressed to cancel overdrive. The TCIL indicates overdrive cancel mode activated (lamp on) and electronic pressure control (EPC) circuit shorted (lamp flashing) or monitored sensor failure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis Overdrive Switch: Flow of Diagnosis 1. Verify the customer concern by operating the transmission external control. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged shift lock actuator - Damaged transmission control switch - Failed fuse(s) Damaged wiring harness - Loose or corroded connections 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 5612 Overdrive Switch: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 5613 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 5614 Overdrive Switch: Pinpoint Tests Part 1 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 5615 Part 2 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 5616 Part 3 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 5617 Part 4 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 5618 Part 5 Of 5 Part 1 Of 3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 5619 Part 2 Of 3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 5620 Part 3 Of 3 Part 1 Of 4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 5621 Part 2 Of 4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 5622 Part 3 Of 4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 5623 Part 4 Of 4 Part 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 5624 Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 5625 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Page 5626 Overdrive Switch: Service and Repair REMOVAL 1. Remove the transmission control switch (TCS). (1) Remove the TCS cover. (2) Remove the TCS. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Description and Operation Shift Interlock Switch: Description and Operation The brake shift interlock actuator prevents moving the shift lever out of the PARK position unless the brake pedal is depressed. The actuator receives a signal from the brake on/off (BOO) switch that allows movement of the shift lever. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > New Digital Transmission Range Sensor - Service Tip Transmission Position Switch/Sensor: Technical Service Bulletins New Digital Transmission Range Sensor - Service Tip Article No. 96-24-10 11/18/96 TRANSMISSION - E40D - 4R70W - 4R44E - 5R55E - NEW DIGITAL TRANSMISSION RANGE SENSOR - DIAGNOSIS SERVICE TIP LINCOLN-MERCURY: 1997 MARK VIII LIGHT TRUCK: 1997 AEROSTAR, ECONOLINE, EXPEDITION, EXPLORER, F-150, F-250, MOUNTAINEER ISSUE: Beginning with Job 1 1997, some vehicles will be equipped with a new Digital Transmission Range (DTR) sensor. The DTR sensor is located on the outside of the transmission (Figure 1) at the outer manual lever. ACTION: Refer to the following text to properly diagnose a concern with the DTR sensor. The new DTR sensor completes the start circuit in "Park" and "Neutral," the backup lamp circuit in "Reverse" and the neutral sense circuit (4X4 only) in "Neutral." The DTR sensor also opens/closes a set of four (4) switches that are monitored by the Powertrain Control Module (PCM) to determine the position of the transmission manual lever. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > New Digital Transmission Range Sensor - Service Tip > Page 5634 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > New Digital Transmission Range Sensor - Service Tip > Page 5635 To properly diagnose the DTR sensor, use the NGS, Rotunda Transmission Tester with TR/MLP Cable "E" (Figure 2) and the new DTR Sensor Overlay (Figure 4), while following the procedures outlined in the appropriate model 1997 Service Manual, Section 07-01 or appropriate model 1997 Workshop Manual, Section 307-01. The new DTR Sensor Overlay (007-00131) and updated Tester Manual was sent to all dealers in August 1996. The TR/MLP Cable "E" (007-00111) was sent to all dealers in June 1995 (refer to TSB 95-19-7). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > New Digital Transmission Range Sensor - Service Tip > Page 5636 When using Cable "E" (Figure 3) to diagnose the DTR sensor, the slide switch must be in the "Digital" position and the "Black" 12-pin connector installed on the sensor. Having the slide switch in the incorrect position or using the incorrect 12-pin connector will result in misdiagnosis and possible replacement of a good component. For diagnosis of the DTR sensor, always refer to the appropriate model 1997 Service Manual, Section 07.01 or appropriate model 1997 Workshop Manual, Section 3O7-01 for proper procedure and required equipment. OTHER APPLICABLE ARTICLES: 95-19-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 503000, 503300, 504000, 601300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 5637 Transmission Position Switch/Sensor: Specifications TORQUE SPECIFICATIONS DTR Sensor Bolts ................................................................................................................................ ..................................... 7-10 Nm (62-89 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 5638 Transmission Position Switch/Sensor: Locations Transmission View The Digital Transmission Range Sensor is located at left side of the automatic transmission. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 5639 Digital Transmission Range Sensor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 5640 Transmission Position Switch/Sensor: Adjustments NOTE: Use Digital Transmission Range (DTR) Sensor Alignment Tool to align both TR and DTR sensors. 1. Raise and support vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Disconnect the manual lever shift control cable. 3. Disconnect the TR or DTR electrical connector. 4. Remove the manual control lever. (1) Remove the nut. (2) Remove the lever. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. 5. Loosen the TR or DTR bolts. 6. Use DTR sensor alignment tool, to align the DTR or TR sensor slots. NOTE: Manual shift lever must be in the neutral position. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 5641 7. Tighten the DTR or TR sensor bolts. 8. Install the manual control lever. (1) Position the manual control lever. (2) Install a new manual lever shaft outer nut. 9. With the manual lever in overdrive connect the shift lever control cable. 10. Install the DTR sensor electrical connector. 11. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications TORQUE SPECIFICATIONS Output Shaft Speed (OSS) Sensor Bolt .......................................................................................................................................... 8-16 Nm (6-12 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 5645 Transmission Speed Sensor: Locations Transmission View The Output Shaft Speed Sensor is located at left side of transmission. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 5646 Output Shaft Speed Sensor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Selector Switch: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions Four Wheel Drive Selector Switch: Customer Interest Transfer Case - Multiple Electrical Malfunctions Article No. 01-16-6 08/20/01 ^ LAMP - 4X4 "LOW RANGE" LIGHT DIMLY LIT ^ SWITCHES - TRANSFER CASE MODE SWITCH - 4X4 HI/LOW SWITCH SHORTED OUT ^ WINDSHIELD WIPERS - INTERMITTENT WIPERS ERRATIC OR INOPERABLE ^ TRANSFER CASE - WATER PRESENT IN TRANSFER CASE FORD: 1997 EXPEDITION, F-150, F-250 LD This article is being republished in its entirety to update the labor time. ISSUE Water may be present in the transfer case on some vehicles. This may cause: ^ Transfer Case Mode Switch to become inoperative ^ The 4X4 "Low Range" light to appear dimly lit ^ The intermittent wipers to become erratic or inoperative ^ Vehicle Speed Sensor (VSS) Diagnostic Trouble Codes (DTCs) P0500, P0503, P1500, and P1501 to be set. This may be caused by water splashing into the transfer case through the vent tube assembly, possibly causing the transfer case mode switch to short out, and/or the VSS gear to swell and set the VSS DTCs listed above. Shorting out the transfer case mode switch may cause the intermittent wiper mode to function erratically, as well as possibly causing the 4X4 light to work incorrectly. ACTION Inspect, diagnose, and/or replace the necessary components. Refer to the following Service Procedure for details. SERVICE PROCEDURE Procedure for VSS Gear: 1. Inspect VSS gear in the transfer case for looseness. 2. Replace Gear (C80Z-17285-B) as necessary. Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Mode Switch: 1. Check resistance of the Transfer Case Mode Switch. 2. The resistance of the switch should be at least 100,000 ohms. If it is less, replace the switch (3-Position Switch, E7TZ-7E440-A, manual shift only). Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Vent Replacement: 1. Remove old vent hose from fitting on front of transfer case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Selector Switch: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 5656 2. Attach end of new Vent Hose (F75Z-7A246-M) to fitting, and route the hose up over the top of the transfer case (Figure 1). 3. Attach the clip on the vent hose to the top of the vertical rib on the transfer case extension housing to support the end of the hose (Figure 2). NOTE FOR ALL WATER CONCERNS, DRAIN AND REFILL THE TRANSFER CASE WITH FRESH FLUID (XT-2-QDX), AND REPLACE THE VENT HOSE WITH THE REVISED PART. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Selector Switch: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 5657 SUPERSEDES:97-11-19 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011606A Drain And Refill Transfer 1.2 Hrs. Case, Inspect And/Or Replace VSS Gear And Transfer Case Mode Switch, And Install Vent Kit DEALER CODING CONDITION BASIC PART NO. CODE 7D494 49 OASIS CODES: 202000, 206000, 508000, 508300, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Selector Switch: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions Four Wheel Drive Selector Switch: All Technical Service Bulletins Transfer Case - Multiple Electrical Malfunctions Article No. 01-16-6 08/20/01 ^ LAMP - 4X4 "LOW RANGE" LIGHT DIMLY LIT ^ SWITCHES - TRANSFER CASE MODE SWITCH - 4X4 HI/LOW SWITCH SHORTED OUT ^ WINDSHIELD WIPERS - INTERMITTENT WIPERS ERRATIC OR INOPERABLE ^ TRANSFER CASE - WATER PRESENT IN TRANSFER CASE FORD: 1997 EXPEDITION, F-150, F-250 LD This article is being republished in its entirety to update the labor time. ISSUE Water may be present in the transfer case on some vehicles. This may cause: ^ Transfer Case Mode Switch to become inoperative ^ The 4X4 "Low Range" light to appear dimly lit ^ The intermittent wipers to become erratic or inoperative ^ Vehicle Speed Sensor (VSS) Diagnostic Trouble Codes (DTCs) P0500, P0503, P1500, and P1501 to be set. This may be caused by water splashing into the transfer case through the vent tube assembly, possibly causing the transfer case mode switch to short out, and/or the VSS gear to swell and set the VSS DTCs listed above. Shorting out the transfer case mode switch may cause the intermittent wiper mode to function erratically, as well as possibly causing the 4X4 light to work incorrectly. ACTION Inspect, diagnose, and/or replace the necessary components. Refer to the following Service Procedure for details. SERVICE PROCEDURE Procedure for VSS Gear: 1. Inspect VSS gear in the transfer case for looseness. 2. Replace Gear (C80Z-17285-B) as necessary. Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Mode Switch: 1. Check resistance of the Transfer Case Mode Switch. 2. The resistance of the switch should be at least 100,000 ohms. If it is less, replace the switch (3-Position Switch, E7TZ-7E440-A, manual shift only). Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Vent Replacement: 1. Remove old vent hose from fitting on front of transfer case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Selector Switch: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 5663 2. Attach end of new Vent Hose (F75Z-7A246-M) to fitting, and route the hose up over the top of the transfer case (Figure 1). 3. Attach the clip on the vent hose to the top of the vertical rib on the transfer case extension housing to support the end of the hose (Figure 2). NOTE FOR ALL WATER CONCERNS, DRAIN AND REFILL THE TRANSFER CASE WITH FRESH FLUID (XT-2-QDX), AND REPLACE THE VENT HOSE WITH THE REVISED PART. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Selector Switch: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 5664 SUPERSEDES:97-11-19 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011606A Drain And Refill Transfer 1.2 Hrs. Case, Inspect And/Or Replace VSS Gear And Transfer Case Mode Switch, And Install Vent Kit DEALER CODING CONDITION BASIC PART NO. CODE 7D494 49 OASIS CODES: 202000, 206000, 508000, 508300, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Page 5665 Four Wheel Drive Selector Switch: Specifications TORQUE SPECIFICATIONS Shift Range Selector Switch Screws ........................................................................................................................................... 2-3 Nm (18-26 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Page 5666 4 Wheel Drive Mode Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Page 5667 Four Wheel Drive Selector Switch: Description and Operation The 4WD mode switch is a rotary switch which allows the vehicle operator to choose between 2WD, A4WD, 4WD HIGH, and LOW range positions. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Page 5668 Four Wheel Drive Selector Switch: Service and Repair REMOVAL 1. Remove the center instrument panel trim plate. 2. Remove the shift range selector switch. (1) Remove the shift range selector switch knob. (2) Disconnect the shift range selector switch electrical connector. (3) Remove the two shift range selector switch screws. (4) Remove the shift range selector switch. INSTALLATION 1. Install the shift range selector switch. (1) Position the shift range selector switch. (2) Install the bolts. (3) Install the electrical connectors. (4) Install the knob. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Page 5669 2. Install the center instrument panel trim panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Speed Sensor: > 01-16-6 > Aug > 01 > Transfer Case Multiple Electrical Malfunctions Speed Sensor: Customer Interest Transfer Case - Multiple Electrical Malfunctions Article No. 01-16-6 08/20/01 ^ LAMP - 4X4 "LOW RANGE" LIGHT DIMLY LIT ^ SWITCHES - TRANSFER CASE MODE SWITCH - 4X4 HI/LOW SWITCH SHORTED OUT ^ WINDSHIELD WIPERS - INTERMITTENT WIPERS ERRATIC OR INOPERABLE ^ TRANSFER CASE - WATER PRESENT IN TRANSFER CASE FORD: 1997 EXPEDITION, F-150, F-250 LD This article is being republished in its entirety to update the labor time. ISSUE Water may be present in the transfer case on some vehicles. This may cause: ^ Transfer Case Mode Switch to become inoperative ^ The 4X4 "Low Range" light to appear dimly lit ^ The intermittent wipers to become erratic or inoperative ^ Vehicle Speed Sensor (VSS) Diagnostic Trouble Codes (DTCs) P0500, P0503, P1500, and P1501 to be set. This may be caused by water splashing into the transfer case through the vent tube assembly, possibly causing the transfer case mode switch to short out, and/or the VSS gear to swell and set the VSS DTCs listed above. Shorting out the transfer case mode switch may cause the intermittent wiper mode to function erratically, as well as possibly causing the 4X4 light to work incorrectly. ACTION Inspect, diagnose, and/or replace the necessary components. Refer to the following Service Procedure for details. SERVICE PROCEDURE Procedure for VSS Gear: 1. Inspect VSS gear in the transfer case for looseness. 2. Replace Gear (C80Z-17285-B) as necessary. Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Mode Switch: 1. Check resistance of the Transfer Case Mode Switch. 2. The resistance of the switch should be at least 100,000 ohms. If it is less, replace the switch (3-Position Switch, E7TZ-7E440-A, manual shift only). Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Vent Replacement: 1. Remove old vent hose from fitting on front of transfer case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Speed Sensor: > 01-16-6 > Aug > 01 > Transfer Case Multiple Electrical Malfunctions > Page 5678 2. Attach end of new Vent Hose (F75Z-7A246-M) to fitting, and route the hose up over the top of the transfer case (Figure 1). 3. Attach the clip on the vent hose to the top of the vertical rib on the transfer case extension housing to support the end of the hose (Figure 2). NOTE FOR ALL WATER CONCERNS, DRAIN AND REFILL THE TRANSFER CASE WITH FRESH FLUID (XT-2-QDX), AND REPLACE THE VENT HOSE WITH THE REVISED PART. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Speed Sensor: > 01-16-6 > Aug > 01 > Transfer Case Multiple Electrical Malfunctions > Page 5679 SUPERSEDES:97-11-19 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011606A Drain And Refill Transfer 1.2 Hrs. Case, Inspect And/Or Replace VSS Gear And Transfer Case Mode Switch, And Install Vent Kit DEALER CODING CONDITION BASIC PART NO. CODE 7D494 49 OASIS CODES: 202000, 206000, 508000, 508300, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions Speed Sensor: All Technical Service Bulletins Transfer Case - Multiple Electrical Malfunctions Article No. 01-16-6 08/20/01 ^ LAMP - 4X4 "LOW RANGE" LIGHT DIMLY LIT ^ SWITCHES - TRANSFER CASE MODE SWITCH - 4X4 HI/LOW SWITCH SHORTED OUT ^ WINDSHIELD WIPERS - INTERMITTENT WIPERS ERRATIC OR INOPERABLE ^ TRANSFER CASE - WATER PRESENT IN TRANSFER CASE FORD: 1997 EXPEDITION, F-150, F-250 LD This article is being republished in its entirety to update the labor time. ISSUE Water may be present in the transfer case on some vehicles. This may cause: ^ Transfer Case Mode Switch to become inoperative ^ The 4X4 "Low Range" light to appear dimly lit ^ The intermittent wipers to become erratic or inoperative ^ Vehicle Speed Sensor (VSS) Diagnostic Trouble Codes (DTCs) P0500, P0503, P1500, and P1501 to be set. This may be caused by water splashing into the transfer case through the vent tube assembly, possibly causing the transfer case mode switch to short out, and/or the VSS gear to swell and set the VSS DTCs listed above. Shorting out the transfer case mode switch may cause the intermittent wiper mode to function erratically, as well as possibly causing the 4X4 light to work incorrectly. ACTION Inspect, diagnose, and/or replace the necessary components. Refer to the following Service Procedure for details. SERVICE PROCEDURE Procedure for VSS Gear: 1. Inspect VSS gear in the transfer case for looseness. 2. Replace Gear (C80Z-17285-B) as necessary. Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Mode Switch: 1. Check resistance of the Transfer Case Mode Switch. 2. The resistance of the switch should be at least 100,000 ohms. If it is less, replace the switch (3-Position Switch, E7TZ-7E440-A, manual shift only). Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Vent Replacement: 1. Remove old vent hose from fitting on front of transfer case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 5685 2. Attach end of new Vent Hose (F75Z-7A246-M) to fitting, and route the hose up over the top of the transfer case (Figure 1). 3. Attach the clip on the vent hose to the top of the vertical rib on the transfer case extension housing to support the end of the hose (Figure 2). NOTE FOR ALL WATER CONCERNS, DRAIN AND REFILL THE TRANSFER CASE WITH FRESH FLUID (XT-2-QDX), AND REPLACE THE VENT HOSE WITH THE REVISED PART. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 5686 SUPERSEDES:97-11-19 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011606A Drain And Refill Transfer 1.2 Hrs. Case, Inspect And/Or Replace VSS Gear And Transfer Case Mode Switch, And Install Vent Kit DEALER CODING CONDITION BASIC PART NO. CODE 7D494 49 OASIS CODES: 202000, 206000, 508000, 508300, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Page 5687 Speed Sensor: Specifications TORQUE SPECIFICATIONS Output Speed Sensor Bolt ........................................................................................................................................................... 3-6 Nm (27-53 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns PROM - Programmable Read Only Memory: Customer Interest PCM - MIL ON/Multiple DTC's Set/Driveability Concerns Article No. 97-26-19 12/22/97 ^ HESITATION/SURGE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ MALFUNCTION INDICATOR LAMP (MIL) - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 ^ ROUGH IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ STALL - LOW SPEEDS AND OR IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 F-350, NAVIGATOR This TSB article is being republished in its entirety to correct the PCM Application Chart and include a reference to TSB 97-26-17. CALIBRATION: 7-46D-R07, 7-46E-R07, 7-46F-R07, 7-46R-R07, 7-46T-R07, 7-46U-R07, 7-46F-R10, 7-46U-R10, 7-48J-R05, 7-48U-R05, 7-48J-R10, 7-48U-R10, 8-46D-R05, 8-46E-R05, 8-46F-R05, 8-46R-RO5, 8-46T-R05, 8-46U-R05, 8-48J-R05 WARNING: THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS. ISSUE: The Malfunction Indicator Lamp (MIL) may illuminate on vehicles with a 4.6L or 5.4L engine, and one or more of the following concerns may be present: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 5696 ^ MIL lamp on with Diagnostic Trouble Codes (DTCs): P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 ^ Rough idle ^ Engine miss ^ Hesitation/Surge ^ Buck/Jerk ^ Stall at idle ^ Near stall ^ Stall at low speeds This may be caused by the Heated Exhaust Gas Oxygen (HEGO) monitor calibration not allowing enough time for proper monitoring. ACTION: Reprogram the Powertrain Control Module (PCM) and replace the HEGO sensor(s). Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal diagnostics as outlined in the 1997 Powertrain Control/Emissions Diagnosis (PC/ED) On-Board Diagnostics II (OBD-II) Service Manual and repair as required. 2. If the concern still exists or no problems were found, reprogram the PCM using Service Bay Diagnostic System (SDBS) or New Generation Star (NGS) Tester. Refer to the following Recalibration Cross Reference Chart for correct PCM calibration. 3. Replace the HEGO sensor(s) (F88z-9F472-AB) as required. NOTE: FOR 5.4L APPLICATIONS, DEALERS MUST ALSO PERFORM TSB 97-26-17 TO INSTALL THE DRAIN TUBE ON THE LOWER A/C EVAPORATOR DRAIN. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 5697 NOTE: PCM REPLACEMENT IS NOT AUTHORIZED BY THIS TSB. REFER TO THE POWERTRAIN CONTROL/EMISSIONS DIAGNOSIS (PC/ED) SERVICE MANUAL FOR APPROPRIATE DIAGNOSTIC PROCEDURES IF PCM HARDWARE CONCERNS EXIST. Obtain an Authorized Modification Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME F88Z-9F472-AB Heated Exhaust Gas Oxygen (HEGO) Sensor OTHER APPLICABLE ARTICLES: 97-26-17 SUPERSEDES: 97-21-13 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 972619A Reprogram Powertrain 0.2 Hr. Control Module (PCM) 972619DL Replace Heated Exhaust 0.3 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Left Side 972619DR Replace Heated Exhaust 0.6 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Right Side 972619DT Replace Heated Exhaust 0.8 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Both 972619ET Replace Heated Exhaust 0.4 Hr. Gas Oxygen (HEGO) Sensors - 4.6L Both 972619E Replace Heated Exhaust 0.3 Hr. Gas Oxygen (H EGO) Sensors - 4.6L One DEALER CODING CONDITION BASIC PART NO. CODE 9F472 42 OASIS CODES: 607000, 607400, 607700, 608000, 608400, Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 5698 611000, 611500, 612000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 97-13-17 > Jun > 97 > PCM - MIL ON/DTC P0446 Set/Stall/Knock PROM - Programmable Read Only Memory: Customer Interest PCM - MIL ON/DTC P0446 Set/Stall/Knock Article No. 97-13-17 06/23/97 ^ MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODE (DTC) P0446 STORED IN MEMORY - VEHICLES BUILT THROUGH 3/97 ^ MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - STALL ON DECELERATION AND/OR SPARK KNOCK AT HOT AMBIENT TEMPERATURES - VEHICLES BUILT THROUGH 3/97 WITH 4.6L ENGINE ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODE (DTC) P0446 STORED IN MEMORY - VEHICLES BUILT THROUGH 3/97 LIGHT TRUCK: 1997 EXPEDITION CALIBRATION: 7-48J-R05, 7-48U-R05, 7-46F-R07, 7-46U-R07 WARNING: THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS. ISSUE: The Malfunction Indicator Lamp (MIL) may illuminate with Diagnostic Trouble Code (DTC) P0446 (Evaporative Emissions Control System Vent Control Malfunction) stored in continuous memory on some 4.6L and 5.4L Expeditions. Some 4.6L Expeditions may experience a stall on deceleration and/or spark knock at hot ambient temperatures. These concerns may be caused by the Powertrain Control Module (PCM) calibration. ACTION: Reprogram the PCM. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE: REGIONAL APPROVAL MUST BE OBTAINED WHEN IT IS NECESSARY TO REPLACE THE PCM. EMERGENCY ORDERS ONLY WILL BE FILLED AS SHELF STOCK OF PCMs ARE LIMITED. 1. Conduct normal diagnostics and repair as required. 2. Check to verify vehicle does not have the latest calibration. If it does not, reprogram the PCM with the appropriate calibration, referring to the PCM Application Chart above using the June, 1997 or later CD-ROM. 3. After calibration update is complete, continue with normal diagnostics (visual inspection and road test) to determine root cause for DTC P1450 (formerly P0446) using Pinpoint Test HX56 on Page 5A-464 of the 1997 Powertrain Control/Emissions Diagnosis (PC/ED) Service Manual. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 97-13-17 > Jun > 97 > PCM - MIL ON/DTC P0446 Set/Stall/Knock > Page 5703 Obtain an Authorized Modification Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper to Bumper Warranty Coverage And Emission Warranty Coverage OPERATION DESCRIPTION TIME 971317A Reprogram Powertrain 0.2 Hr. Control Module (PCM) DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 42 OASIS CODES: 206000, 615000, 615500, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 5709 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 5710 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - MIL ON/Multiple DTC's Set/Driveability Concerns Article No. 97-26-19 12/22/97 ^ HESITATION/SURGE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ MALFUNCTION INDICATOR LAMP (MIL) - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 ^ ROUGH IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ STALL - LOW SPEEDS AND OR IDLE - MIL ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P115O, P1151, P1152, P1157, P1158 IN MEMORY - VEHICLES BUILT THROUGH 11/97 ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 STORED - VEHICLES BUILT THROUGH 11/97 LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 F-350, NAVIGATOR This TSB article is being republished in its entirety to correct the PCM Application Chart and include a reference to TSB 97-26-17. CALIBRATION: 7-46D-R07, 7-46E-R07, 7-46F-R07, 7-46R-R07, 7-46T-R07, 7-46U-R07, 7-46F-R10, 7-46U-R10, 7-48J-R05, 7-48U-R05, 7-48J-R10, 7-48U-R10, 8-46D-R05, 8-46E-R05, 8-46F-R05, 8-46R-RO5, 8-46T-R05, 8-46U-R05, 8-48J-R05 WARNING: THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS. ISSUE: The Malfunction Indicator Lamp (MIL) may illuminate on vehicles with a 4.6L or 5.4L engine, and one or more of the following concerns may be present: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 5715 ^ MIL lamp on with Diagnostic Trouble Codes (DTCs): P0133, P0135, P0141, P0153, P0155, P0161, P1130, P1131, P1132, P1137, P1138, P1150, P1151, P1152, P1157, P1158 ^ Rough idle ^ Engine miss ^ Hesitation/Surge ^ Buck/Jerk ^ Stall at idle ^ Near stall ^ Stall at low speeds This may be caused by the Heated Exhaust Gas Oxygen (HEGO) monitor calibration not allowing enough time for proper monitoring. ACTION: Reprogram the Powertrain Control Module (PCM) and replace the HEGO sensor(s). Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal diagnostics as outlined in the 1997 Powertrain Control/Emissions Diagnosis (PC/ED) On-Board Diagnostics II (OBD-II) Service Manual and repair as required. 2. If the concern still exists or no problems were found, reprogram the PCM using Service Bay Diagnostic System (SDBS) or New Generation Star (NGS) Tester. Refer to the following Recalibration Cross Reference Chart for correct PCM calibration. 3. Replace the HEGO sensor(s) (F88z-9F472-AB) as required. NOTE: FOR 5.4L APPLICATIONS, DEALERS MUST ALSO PERFORM TSB 97-26-17 TO INSTALL THE DRAIN TUBE ON THE LOWER A/C EVAPORATOR DRAIN. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 5716 NOTE: PCM REPLACEMENT IS NOT AUTHORIZED BY THIS TSB. REFER TO THE POWERTRAIN CONTROL/EMISSIONS DIAGNOSIS (PC/ED) SERVICE MANUAL FOR APPROPRIATE DIAGNOSTIC PROCEDURES IF PCM HARDWARE CONCERNS EXIST. Obtain an Authorized Modification Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME F88Z-9F472-AB Heated Exhaust Gas Oxygen (HEGO) Sensor OTHER APPLICABLE ARTICLES: 97-26-17 SUPERSEDES: 97-21-13 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 972619A Reprogram Powertrain 0.2 Hr. Control Module (PCM) 972619DL Replace Heated Exhaust 0.3 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Left Side 972619DR Replace Heated Exhaust 0.6 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Right Side 972619DT Replace Heated Exhaust 0.8 Hr. Gas Oxygen (HEGO) Sensors - 5.4L Both 972619ET Replace Heated Exhaust 0.4 Hr. Gas Oxygen (HEGO) Sensors - 4.6L Both 972619E Replace Heated Exhaust 0.3 Hr. Gas Oxygen (H EGO) Sensors - 4.6L One DEALER CODING CONDITION BASIC PART NO. CODE 9F472 42 OASIS CODES: 607000, 607400, 607700, 608000, 608400, Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 97-26-19 > Dec > 97 > PCM - MIL ON/Multiple DTC's Set/Driveability Concerns > Page 5717 611000, 611500, 612000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 97-13-17 > Jun > 97 > PCM - MIL ON/DTC P0446 Set/Stall/Knock PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - MIL ON/DTC P0446 Set/Stall/Knock Article No. 97-13-17 06/23/97 ^ MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODE (DTC) P0446 STORED IN MEMORY - VEHICLES BUILT THROUGH 3/97 ^ MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - STALL ON DECELERATION AND/OR SPARK KNOCK AT HOT AMBIENT TEMPERATURES - VEHICLES BUILT THROUGH 3/97 WITH 4.6L ENGINE ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODE (DTC) P0446 STORED IN MEMORY - VEHICLES BUILT THROUGH 3/97 LIGHT TRUCK: 1997 EXPEDITION CALIBRATION: 7-48J-R05, 7-48U-R05, 7-46F-R07, 7-46U-R07 WARNING: THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS. ISSUE: The Malfunction Indicator Lamp (MIL) may illuminate with Diagnostic Trouble Code (DTC) P0446 (Evaporative Emissions Control System Vent Control Malfunction) stored in continuous memory on some 4.6L and 5.4L Expeditions. Some 4.6L Expeditions may experience a stall on deceleration and/or spark knock at hot ambient temperatures. These concerns may be caused by the Powertrain Control Module (PCM) calibration. ACTION: Reprogram the PCM. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE: REGIONAL APPROVAL MUST BE OBTAINED WHEN IT IS NECESSARY TO REPLACE THE PCM. EMERGENCY ORDERS ONLY WILL BE FILLED AS SHELF STOCK OF PCMs ARE LIMITED. 1. Conduct normal diagnostics and repair as required. 2. Check to verify vehicle does not have the latest calibration. If it does not, reprogram the PCM with the appropriate calibration, referring to the PCM Application Chart above using the June, 1997 or later CD-ROM. 3. After calibration update is complete, continue with normal diagnostics (visual inspection and road test) to determine root cause for DTC P1450 (formerly P0446) using Pinpoint Test HX56 on Page 5A-464 of the 1997 Powertrain Control/Emissions Diagnosis (PC/ED) Service Manual. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 97-13-17 > Jun > 97 > PCM - MIL ON/DTC P0446 Set/Stall/Knock > Page 5722 Obtain an Authorized Modification Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper to Bumper Warranty Coverage And Emission Warranty Coverage OPERATION DESCRIPTION TIME 971317A Reprogram Powertrain 0.2 Hr. Control Module (PCM) DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 42 OASIS CODES: 206000, 615000, 615500, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 97-9-8 > Apr > 97 > PCM - Reprogramming Tips PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - Reprogramming Tips Article No. 97-9-8 04/28/97 POWERTRAIN CONTROL MODULE - REPROGRAM POWERTRAIN CONTROL MODULE (PCM) - SERVICE PROCEDURES - SERVICE TIP FORD: 1994-97 CROWN VICTORIA, MUSTANG, THUNDERBIRD 1996-97 CONTOUR, ESCORT, PROBE, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR, GRAND MARQUIS 1995-97 CONTINENTAL, TOWN CAR 1996-97 MARK VIII, MYSTIQUE, SABLE, TRACER LIGHT TRUCK: 1994-97 ECONOLINE, F-150-350 SERIES 1995-97 RANGER 1995-98 WINDSTAR 1996 BRONCO 1996-97 AEROSTAR, EXPLORER 1997 EXPEDITION, MOUNTAINEER This TSB article is being republished in its entirety to include Windstar. ISSUE: Powertrain Control Modules (PCMs) no longer need to be replaced when servicing driveability concerns. The only time a PCM needs replacing is when it can no longer be reprogrammed and/or is damaged. In all other cases, the PCM must be reprogrammed and NOT REPLACED. ACTION: Use the following Service Procedure to properly reprogram a PCM. SERVICE PROCEDURE PCM REPROGRAMMING USING SBDS 1. At the Main menu, select Powertrain and enter the Vehicle Identification Number (VIN). Select "Continue." 2. From the Powertrain menu, select Electronic Engine category. 3. Scroll through the "Tool List" to PCM Reprogramming and select "Continue." 4. Any TSBs or Recalls for the entered vehicle will be displayed. There is up to a 6 week delay for TSB/Recall information updates on SBDS. New TSBs/Recalls may not appear or only the TSB number will be displayed even though the new calibration is on the current calibration CD-ROM. Also, if the vehicle calibration is being updated because of a Special Service Message, Broadcast Message or the PCM was replaced and requires calibration, no screen may appear. This is not a concern and will not prevent programming updates or being paid for programming updates. 5. Follow all hook-up instructions and continue as prompted to the calibration screen. Typically, a list of calibration numbers will appear. Answer as appropriate for the vehicle and select "Continue." SBDS will then validate the information entered against the information read in the PCM, and any mismatch of software or hardware will be displayed for technician action. 6. Insert the proper calibration or the latest level CD-ROM when prompted and follow the instructions as displayed by SBDS. Do not crank the engine. SBDS will update the engine calibration to the latest level calibration for the selected calibration. 7. After programming is complete, SBDS will display a representation of the Authorized Modification Decal with the Engineering Part Number for the PCM installed. It is important that the label be completed and attached to the vehicle. S8DS will also automatically print a copy of the vehicle log for filing with the Repair Order. 8. Selecting "Continue" will call for a KOEO self test. Any hard faults present after performing self test were not caused by reprogramming. The calibration has now been validated and the PCM is operating properly. Unless directed by other Service Procedures, the vehicle can be released to Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 97-9-8 > Apr > 97 > PCM - Reprogramming Tips > Page 5727 the customer. PCM REPROGRAMMING WITH SBTS/NGS 1. Select "NGS," then follow procedure "Touring PLM Recalibration." 2. Be sure to use cable with oversized DCL connector. The oversized connector incorporates an 18-volt transformer supplying the required voltage to reprogram the PCM. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-25-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 5733 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 5734 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 97-9-8 > Apr > 97 > PCM - Reprogramming Tips PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - Reprogramming Tips Article No. 97-9-8 04/28/97 POWERTRAIN CONTROL MODULE - REPROGRAM POWERTRAIN CONTROL MODULE (PCM) - SERVICE PROCEDURES - SERVICE TIP FORD: 1994-97 CROWN VICTORIA, MUSTANG, THUNDERBIRD 1996-97 CONTOUR, ESCORT, PROBE, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR, GRAND MARQUIS 1995-97 CONTINENTAL, TOWN CAR 1996-97 MARK VIII, MYSTIQUE, SABLE, TRACER LIGHT TRUCK: 1994-97 ECONOLINE, F-150-350 SERIES 1995-97 RANGER 1995-98 WINDSTAR 1996 BRONCO 1996-97 AEROSTAR, EXPLORER 1997 EXPEDITION, MOUNTAINEER This TSB article is being republished in its entirety to include Windstar. ISSUE: Powertrain Control Modules (PCMs) no longer need to be replaced when servicing driveability concerns. The only time a PCM needs replacing is when it can no longer be reprogrammed and/or is damaged. In all other cases, the PCM must be reprogrammed and NOT REPLACED. ACTION: Use the following Service Procedure to properly reprogram a PCM. SERVICE PROCEDURE PCM REPROGRAMMING USING SBDS 1. At the Main menu, select Powertrain and enter the Vehicle Identification Number (VIN). Select "Continue." 2. From the Powertrain menu, select Electronic Engine category. 3. Scroll through the "Tool List" to PCM Reprogramming and select "Continue." 4. Any TSBs or Recalls for the entered vehicle will be displayed. There is up to a 6 week delay for TSB/Recall information updates on SBDS. New TSBs/Recalls may not appear or only the TSB number will be displayed even though the new calibration is on the current calibration CD-ROM. Also, if the vehicle calibration is being updated because of a Special Service Message, Broadcast Message or the PCM was replaced and requires calibration, no screen may appear. This is not a concern and will not prevent programming updates or being paid for programming updates. 5. Follow all hook-up instructions and continue as prompted to the calibration screen. Typically, a list of calibration numbers will appear. Answer as appropriate for the vehicle and select "Continue." SBDS will then validate the information entered against the information read in the PCM, and any mismatch of software or hardware will be displayed for technician action. 6. Insert the proper calibration or the latest level CD-ROM when prompted and follow the instructions as displayed by SBDS. Do not crank the engine. SBDS will update the engine calibration to the latest level calibration for the selected calibration. 7. After programming is complete, SBDS will display a representation of the Authorized Modification Decal with the Engineering Part Number for the PCM installed. It is important that the label be completed and attached to the vehicle. S8DS will also automatically print a copy of the vehicle log for filing with the Repair Order. 8. Selecting "Continue" will call for a KOEO self test. Any hard faults present after performing self test were not caused by reprogramming. The calibration has now been validated and the PCM is operating properly. Unless directed by other Service Procedures, the vehicle can be released to Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 97-9-8 > Apr > 97 > PCM - Reprogramming Tips > Page 5739 the customer. PCM REPROGRAMMING WITH SBTS/NGS 1. Select "NGS," then follow procedure "Touring PLM Recalibration." 2. Be sure to use cable with oversized DCL connector. The oversized connector incorporates an 18-volt transformer supplying the required voltage to reprogram the PCM. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-25-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair Pressure Regulating Solenoid: Service and Repair REMOVAL 1. Remove the manual control lever shaft. 2. Disconnect the electronic pressure control (EPC) solenoid electrical connector. CAUTION: Do not pull on the wires. This can damage the wires or the connector and can result in transmission solenoid or sensor failure. 3. Remove the EPC solenoid. INSTALLATION 1. Install the EPC solenoid. 2. Connect the electronic pressure control (EPC) solenoid electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Page 5746 3. Install the manual control lever shaft. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications Shift Interlock Solenoid: Specifications TORQUE SPECIFICATIONS Shift Lock Actuator Bolts ...................................................................................................................................................... 7-11 Nm (62.5-98 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 5750 Shift Interlock Solenoid: Service and Repair REMOVAL 1. Remove the steering column. 2. Remove the insert plate and shift lock actuator. (1) Remove the three shift lock actuator bolts. (2) Remove the insert plate and shift lock actuator. 3. Remove the insert plate from the shift lock actuator. - Remove and discard the shift lock actuator clip. NOTE: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced in the field. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams Shift Solenoid: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications Transfer Case Actuator: Specifications TORQUE SPECIFICATIONS Shift Motor Bolts .................................................................................................................................. .................................... 8-11 Nm (71-98 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 5758 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 5759 Transfer Case Actuator: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 5760 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 5761 Transfer Case Actuator: Description and Operation The shifting operation of the front drive axle is accomplished by activating the vacuum motor from a switch located on the instrument panel. It is recommended that shifting of the front axle should be done with the front wheels in a straight ahead position and during light throttle application. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor Transfer Case Actuator: Service and Repair Transfer Case Shift Motor REMOVAL 1. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. Raise and support the vehicle. 2. Disconnect the shift motor electrical connector. 3. Remove the coil wire from the transfer case shift motor electrical connector. 1 Remove the wire connector spacer. 2 Remove the coil wire and pin. Use proper electrical connector pin remover. 4. Remove the transfer case shift motor. 1 Remove the four bolts. 2 Remove the transfer case shift motor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 5764 1. Install the transfer case shift motor. 1 Position the transfer case shift motor. 2 Install the four bolts. 2. Install the coil wire into the transfer case shift motor electrical connector. 1 Install the coil wire and pin. 2 Install the wire connector spacer. 3. Connect the electric shift motor electrical connector. 4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 5765 Transfer Case Actuator: Service and Repair Vacuum Reservoir REMOVAL 1. Remove the right front fender splash shield. 1 Remove the screws. 2 Remove the pushpins. 3 Remove the right front fender splash shield. 2. Remove the engine vacuum reservoir. 1 Remove the bolts. 2 Disconnect the vacuum harness from the engine vacuum reservoir and remove the engine vacuum reservoir. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 5766 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 5767 Transfer Case Actuator: Service and Repair Auxiliary Vacuum Reservoir REMOVAL 1. Remove the front fender splash shield. 2. Disconnect the vacuum harness from the auxiliary vacuum reservoir and the A/C vacuum reservoir. 3. Slide the vacuum reservoir assembly out of the battery tray. 4. Separate the A/C vacuum reservoir from the auxiliary vacuum reservoir. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair Pressure Regulating Solenoid: Service and Repair REMOVAL 1. Remove the manual control lever shaft. 2. Disconnect the electronic pressure control (EPC) solenoid electrical connector. CAUTION: Do not pull on the wires. This can damage the wires or the connector and can result in transmission solenoid or sensor failure. 3. Remove the EPC solenoid. INSTALLATION 1. Install the EPC solenoid. 2. Connect the electronic pressure control (EPC) solenoid electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Page 5773 3. Install the manual control lever shaft. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Specifications Shift Interlock Solenoid: Specifications TORQUE SPECIFICATIONS Shift Lock Actuator Bolts ...................................................................................................................................................... 7-11 Nm (62.5-98 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 5777 Shift Interlock Solenoid: Service and Repair REMOVAL 1. Remove the steering column. 2. Remove the insert plate and shift lock actuator. (1) Remove the three shift lock actuator bolts. (2) Remove the insert plate and shift lock actuator. 3. Remove the insert plate from the shift lock actuator. - Remove and discard the shift lock actuator clip. NOTE: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced in the field. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams Shift Solenoid: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Customer Interest for Accumulator: > 99-18-5 > Sep > 99 > A/T 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift Accumulator: Customer Interest A/T - 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift Article No. 99-18-5 09/06/99 ^ TRANSMISSION CONTROL INDICATOR LAMP (TCIL) - TCIL ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) P0782 STORED IN MEMORY - VEHICLES BUILT BETWEEN 3/15/1997 AND 12/31/1998 AND WITH 4R70W TRANSMISSION ^ TRANSMISSION - 4R70W - DELAYED OR NO 2-3 UPSHIFT - VEHICLES BUILT BETWEEN 3/15/1997 AND 12/31/1998 FORD: 1997-1999 CROWN VICTORIA, MUSTANG, ECONOLINE, EXPEDITION, EXPLORER, F-150, F-250 LD LINCOLN: 1997-1998 MARK VIII 1997-1999 TOWN CAR MERCURY: 1997-1999 GRAND MARQUIS, MOUNTAINEER This TSB article is being republished in its entirety to revise the Service Procedure. ISSUE A perceived 2-3 delayed upshift, primarily when the transmission is cold, may be evident on some vehicles. The Powertrain Control Module (PCM) strategy is designed to delay shifts in some vehicles when Transmission Fluid Temperature (TFT) is below approximately 21°C (70°F) for taster heater warmup. The 2-3 shift may be delayed approximately 14-24 km/h (9-15 mph) when compared to the shift speed charts listed in the appropriate Service or Workshop Manual. A leaking 2-3 accumulator may cause Diagnostic Trouble Code (DTC) P0782. ACTION Verify if delayed upshift is normal cold shift scheduling or a possible leak past the large diameter 2-3 accumulator seal. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Using New Generation Star (NGS) Tester, perform all self tests and record DTCs. 2. Monitor rpm, and gear command Parameter Identification Displays (PIDs) with the NGS Tester during the 2-3 shift. 3. If engine rpm decreases within 1-2 seconds after the gear command has changed on the NGS Tester, then vehicle has upshifted properly and no repair is necessary. If engine rpm does not drop within 1-2 seconds, continue to Step 4. 4. If engine rpm does not drop when the PCM commands third gear, then replace the 2-3 accumulator piston using the revised Accumulator Piston (F7AZ-7H292-AB). Refer to the appropriate Service or Workshop Manual for replacement procedure. PART NUMBER PART NAME F7AZ-7H292-AB Accumulator Piston OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-1-3 WARRANTY STATUS: Eligible Under the Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991805A Replace Accumulator 1.8 Hrs. Piston Per Service Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Customer Interest for Accumulator: > 99-18-5 > Sep > 99 > A/T 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift > Page 5789 Procedure (Includes Diagnosis) 991805B Diagnosis Only (Do Not 0.8 Hr. Use With Operation A) DEALER CODING CONDITION BASIC PART NO CODE 7H292 42 OASIS CODES: 501000, 504000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Customer Interest for Accumulator: > 99-9-6 > May > 99 > A/T 4R70W (Remanufactured) Delayed or No 2-3 Upshift Accumulator: Customer Interest A/T - 4R70W (Remanufactured) Delayed or No 2-3 Upshift Article No. 99-9-6 05/17/99 FORD: 1994-1997 THUNDERBIRD 1995-1998 CROWN VICTORIA 1996-1998 MUSTANG LINCOLN-MERCURY: 1993-1998 MARK VIII 1994-1997 COUGAR 1995-1998 GRAND MARQUIS, TOWN CAR LIGHT TRUCK: 1994-1998 ECONOLINE, F-150 1996-1998 EXPLORER 1997-1998 EXPEDITION, F-25O LD, MOUNTAINEER This concern is ONLY for vehicles with Ford Quality Remanufactured (FQR) 4R70W Transmission Exchange Units With Julian build dates between 062-97 And 04099 (corresponding serial numbers are between R0475797 and R0771887). ISSUE A delayed or no 2-3 upshift, primarily when the transmission is cold, may be evident on some vehicles In some cases, Diagnostic Trouble Code (DTC) P0782 may also be present. This may be caused by fluid pressure leakage past the larger diameter seal of the 2-3 accumulator. ACTION Replace the 2-3 accumulator piston using a revised piston. The revised piston will increase seal/bore interference, eliminating any internal leak relating to the 2-3 accumulator piston reducing the possibility of 2-3 upshift concerns. Refer to the appropriate Service or Workshop Manual for replacement procedure. PART NUMBER PART NAME F7AZ-7H292-AB Piston OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 990906A Replace Accumulator 1.0 Hr. Piston DEALER CODING CONDITION BASIC PART NO. CODE 7H292 42 OASIS CODES: 501000, 504000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Customer Interest for Accumulator: > 97-11-11 > May > 97 > A/T AODE/4R70W Erratic/Prolonged 1-2 Shift Accumulator: Customer Interest A/T - AODE/4R70W Erratic/Prolonged 1-2 Shift Article No. 97-11-11 05/27/97 ^ TRANSMISSION - 4R70W - ERRATIC OR PROLONGED 1-2 SHIFT ^ TRANSMISSION - AODE - ERRATIC OR PROLONGED 1-2 SHIFT FORD: 1992-97 CROWN VICTORIA 1994-97 MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1992-97 GRAND MARQUIS, TOWN CAR 1993-97 MARK VIII 1994-97 COUGAR LIGHT TRUCK: 1994-97 ECONOLINE, F-150 1996-97 EXPLORER 1997 EXPEDITION, MOUNTAINEER ISSUE: Some vehicles may exhibit an erratic or prolonged 1-2 shift. This may be caused by early Accumulator Seal wear which may occur during repeated 1-2, 2-1 shift cycling. The Accumulator side loads in the Case Accumulator Bore and causes the Case Bore to become scuffed. Bore scuffing leads to premature seal wear and eventual intermediate clutch pressure loss, which leads to the loss in 1-2 shift. ACTION: Replace the cast aluminum piston with the one-piece stamped steel piston with bonded lip seals and replace the top Accumulator Spring. These revised parts allow for increased durability. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE: TRANSMISSION CASE REPLACEMENT IS NOT REQUIRED DUE TO 1-2 SHIFT ACCUMULATOR BORE SCUFFING. THE REVISED PISTON ASSEMBLY CAN BE USED WITH SCUFFED SEAL BORE. 1. With the vehicle on a hoist, remove the transmission pan and gasket. Using the Snap Ring Removal Tool, remove the 1-2 Accumulator Piston Retainer. At this time, the spring load will pop the cover and bottom Accumulator Spring out of the bore. 2. Remove the piston and top Accumulator Spring. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Customer Interest for Accumulator: > 97-11-11 > May > 97 > A/T AODE/4R70W Erratic/Prolonged 1-2 Shift > Page 5798 3. Replace the piston and top Accumulator Spring with the new bonded Piston (F7AZ-7F251-AA) and spring (refer to Figure 1 for applications). If not damaged, reinstall the bottom Accumulator Spring and cover. 4. Reinstall the retaining ring. NOTE: DO NOT REUSE THE TRANSMISSION PAN GASKET IF IT IS DAMAGED. 5. Install the transmission pan and gasket. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Customer Interest for Accumulator: > 97-11-11 > May > 97 > A/T AODE/4R70W Erratic/Prolonged 1-2 Shift > Page 5799 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971111A Replace 1-2 Accumulator 0.9 Hr. Components As Required (Includes Pan Removal And Installation) - All Vehicles 971111B Add Time To Clean, 0.1 Hr. Inspect And Reuse Pan Gasket 971111C Post Repair Road Test 0.3 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 7F249 70 OASIS CODES: 501000, 502000, 503000, 504000, 590000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator: > 99-18-5 > Sep > 99 > A/T - 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift Accumulator: All Technical Service Bulletins A/T - 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift Article No. 99-18-5 09/06/99 ^ TRANSMISSION CONTROL INDICATOR LAMP (TCIL) - TCIL ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) P0782 STORED IN MEMORY - VEHICLES BUILT BETWEEN 3/15/1997 AND 12/31/1998 AND WITH 4R70W TRANSMISSION ^ TRANSMISSION - 4R70W - DELAYED OR NO 2-3 UPSHIFT - VEHICLES BUILT BETWEEN 3/15/1997 AND 12/31/1998 FORD: 1997-1999 CROWN VICTORIA, MUSTANG, ECONOLINE, EXPEDITION, EXPLORER, F-150, F-250 LD LINCOLN: 1997-1998 MARK VIII 1997-1999 TOWN CAR MERCURY: 1997-1999 GRAND MARQUIS, MOUNTAINEER This TSB article is being republished in its entirety to revise the Service Procedure. ISSUE A perceived 2-3 delayed upshift, primarily when the transmission is cold, may be evident on some vehicles. The Powertrain Control Module (PCM) strategy is designed to delay shifts in some vehicles when Transmission Fluid Temperature (TFT) is below approximately 21°C (70°F) for taster heater warmup. The 2-3 shift may be delayed approximately 14-24 km/h (9-15 mph) when compared to the shift speed charts listed in the appropriate Service or Workshop Manual. A leaking 2-3 accumulator may cause Diagnostic Trouble Code (DTC) P0782. ACTION Verify if delayed upshift is normal cold shift scheduling or a possible leak past the large diameter 2-3 accumulator seal. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Using New Generation Star (NGS) Tester, perform all self tests and record DTCs. 2. Monitor rpm, and gear command Parameter Identification Displays (PIDs) with the NGS Tester during the 2-3 shift. 3. If engine rpm decreases within 1-2 seconds after the gear command has changed on the NGS Tester, then vehicle has upshifted properly and no repair is necessary. If engine rpm does not drop within 1-2 seconds, continue to Step 4. 4. If engine rpm does not drop when the PCM commands third gear, then replace the 2-3 accumulator piston using the revised Accumulator Piston (F7AZ-7H292-AB). Refer to the appropriate Service or Workshop Manual for replacement procedure. PART NUMBER PART NAME F7AZ-7H292-AB Accumulator Piston OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-1-3 WARRANTY STATUS: Eligible Under the Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991805A Replace Accumulator 1.8 Hrs. Piston Per Service Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator: > 99-18-5 > Sep > 99 > A/T - 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift > Page 5805 Procedure (Includes Diagnosis) 991805B Diagnosis Only (Do Not 0.8 Hr. Use With Operation A) DEALER CODING CONDITION BASIC PART NO CODE 7H292 42 OASIS CODES: 501000, 504000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator: > 99-9-6 > May > 99 > A/T - 4R70W (Remanufactured) Delayed or No 2-3 Upshift Accumulator: All Technical Service Bulletins A/T - 4R70W (Remanufactured) Delayed or No 2-3 Upshift Article No. 99-9-6 05/17/99 FORD: 1994-1997 THUNDERBIRD 1995-1998 CROWN VICTORIA 1996-1998 MUSTANG LINCOLN-MERCURY: 1993-1998 MARK VIII 1994-1997 COUGAR 1995-1998 GRAND MARQUIS, TOWN CAR LIGHT TRUCK: 1994-1998 ECONOLINE, F-150 1996-1998 EXPLORER 1997-1998 EXPEDITION, F-25O LD, MOUNTAINEER This concern is ONLY for vehicles with Ford Quality Remanufactured (FQR) 4R70W Transmission Exchange Units With Julian build dates between 062-97 And 04099 (corresponding serial numbers are between R0475797 and R0771887). ISSUE A delayed or no 2-3 upshift, primarily when the transmission is cold, may be evident on some vehicles In some cases, Diagnostic Trouble Code (DTC) P0782 may also be present. This may be caused by fluid pressure leakage past the larger diameter seal of the 2-3 accumulator. ACTION Replace the 2-3 accumulator piston using a revised piston. The revised piston will increase seal/bore interference, eliminating any internal leak relating to the 2-3 accumulator piston reducing the possibility of 2-3 upshift concerns. Refer to the appropriate Service or Workshop Manual for replacement procedure. PART NUMBER PART NAME F7AZ-7H292-AB Piston OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 990906A Replace Accumulator 1.0 Hr. Piston DEALER CODING CONDITION BASIC PART NO. CODE 7H292 42 OASIS CODES: 501000, 504000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator: > 97-11-11 > May > 97 > A/T - AODE/4R70W Erratic/Prolonged 1-2 Shift Accumulator: All Technical Service Bulletins A/T - AODE/4R70W Erratic/Prolonged 1-2 Shift Article No. 97-11-11 05/27/97 ^ TRANSMISSION - 4R70W - ERRATIC OR PROLONGED 1-2 SHIFT ^ TRANSMISSION - AODE - ERRATIC OR PROLONGED 1-2 SHIFT FORD: 1992-97 CROWN VICTORIA 1994-97 MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1992-97 GRAND MARQUIS, TOWN CAR 1993-97 MARK VIII 1994-97 COUGAR LIGHT TRUCK: 1994-97 ECONOLINE, F-150 1996-97 EXPLORER 1997 EXPEDITION, MOUNTAINEER ISSUE: Some vehicles may exhibit an erratic or prolonged 1-2 shift. This may be caused by early Accumulator Seal wear which may occur during repeated 1-2, 2-1 shift cycling. The Accumulator side loads in the Case Accumulator Bore and causes the Case Bore to become scuffed. Bore scuffing leads to premature seal wear and eventual intermediate clutch pressure loss, which leads to the loss in 1-2 shift. ACTION: Replace the cast aluminum piston with the one-piece stamped steel piston with bonded lip seals and replace the top Accumulator Spring. These revised parts allow for increased durability. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE: TRANSMISSION CASE REPLACEMENT IS NOT REQUIRED DUE TO 1-2 SHIFT ACCUMULATOR BORE SCUFFING. THE REVISED PISTON ASSEMBLY CAN BE USED WITH SCUFFED SEAL BORE. 1. With the vehicle on a hoist, remove the transmission pan and gasket. Using the Snap Ring Removal Tool, remove the 1-2 Accumulator Piston Retainer. At this time, the spring load will pop the cover and bottom Accumulator Spring out of the bore. 2. Remove the piston and top Accumulator Spring. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator: > 97-11-11 > May > 97 > A/T - AODE/4R70W Erratic/Prolonged 1-2 Shift > Page 5814 3. Replace the piston and top Accumulator Spring with the new bonded Piston (F7AZ-7F251-AA) and spring (refer to Figure 1 for applications). If not damaged, reinstall the bottom Accumulator Spring and cover. 4. Reinstall the retaining ring. NOTE: DO NOT REUSE THE TRANSMISSION PAN GASKET IF IT IS DAMAGED. 5. Install the transmission pan and gasket. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator: > 97-11-11 > May > 97 > A/T - AODE/4R70W Erratic/Prolonged 1-2 Shift > Page 5815 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971111A Replace 1-2 Accumulator 0.9 Hr. Components As Required (Includes Pan Removal And Installation) - All Vehicles 971111B Add Time To Clean, 0.1 Hr. Inspect And Reuse Pan Gasket 971111C Post Repair Road Test 0.3 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 7F249 70 OASIS CODES: 501000, 502000, 503000, 504000, 590000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Page 5816 Accumulator: Locations Part 1 Of 2 Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 1-2 Accumulator Accumulator: Service and Repair 1-2 Accumulator REMOVAL 1. Use the (A) Servo Piston Remover Replacer to compress the 1-2 accumulator cover and remove the (B) accumulator piston retaining ring. 2. Remove the (A) 1-2 accumulator cover, the (B) 1-2 accumulator outer spring, the (C) accumulator piston and the (D) 1-2 accumulator inner spring (model dependent). NOTE:Note the location of the 1-2 accumulator outer spring for reference during assembly. Some models may use two 1-2 accumulator outer springs. The accumulator piston may also vary with application. INSTALLATION 1. Install the accumulator piston seal and lower accumulator seal onto the 1-2 accumulator piston. 2. Install the 1-2 accumulator assembly. (1) Install the 1-2 accumulator inner spring (model dependent). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 1-2 Accumulator > Page 5819 (2) Install the accumulator piston. (3) Install the 1-2 accumulator outer spring. (4) Install the cover and seal assembly. 3. Use the (A) Servo Piston Remover Replacer to install the (B) accumulator piston retaining ring. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 1-2 Accumulator > Page 5820 Accumulator: Service and Repair 2-3 Accumulator REMOVAL 1. Remove the main control valve body. 2. Remove the 2-3 shift accumulator spring retainer. 3. Remove the accumulator piston spring and the accumulator piston. INSTALLATION 1. Install the 2-3 accumulator assembly. (1) Install the upper accumulator seal, lower accumulator seal and the accumulator piston. (2) Install the accumulator piston spring. (3) Install the accumulator spring retainer. 2. Install the main control valve body. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Overderive Servo Band Apply Servo: Service and Repair Overderive Servo REMOVAL 1. Remove the main control valve body. 2. Use the (A) Servo Piston Remover/Replacer to compress the servo spring, then remove the (B) overdrive servo retaining ring. CAUTION: If the tool is not available, extreme care must be taken. Spring pressure will force the overdrive servo piston assembly out of the case. Case bore damage can result from trying to pry on the overdrive servo internal retaining ring. 3. Remove the (A) overdrive servo piston and the (B) overdrive servo piston return spring. INSTALLATION 1. Install the overdrive servo piston assembly. (1) Install the overdrive servo piston return spring. (2) Install the overdrive servo piston assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Overderive Servo > Page 5825 2. Use the (A) Servo Piston Remover/Replacer Tool to install the (B) overdrive servo piston retaining ring. 3. Install the main control valve body. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Overderive Servo > Page 5826 Band Apply Servo: Service and Repair Reverse Band Servo REMOVAL 1. Remove the main control valve body. 2. Use the (A) Servo Piston Remover/Replacer to compress the servo spring then remove the (B) reverse band servo retaining ring. 3. Remove the (A) reverse band servo cover, the (B) reverse band servo piston and rod and the (C) reverse band servo spring. NOTE: The length of the rod attached to the piston is graded for three different lengths. Therefore, they should not be installed in any transmission other than the transmission from which they were removed. INSTALLATION NOTE: This is not an ordinary installation procedure and does not compensate for band wear. 1. Install the reverse servo piston and return spring. - Do not install the piston cover. NOTE: Lubricate the reverse piston seal to facilitate assembly and prevent damage to the seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Overderive Servo > Page 5827 2. Install the Servo Piston Selection Tool and tighten the band apply bolt. 3. Attach Dial Indicator With Bracketry. - Position the indicator stem on the flat portion of the reverse servo piston and zero the dial indicator. 4. Loosen the bolt until the piston stops against the tool. 5. Verify the amount of piston travel on the dial indicator is within specification. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Overderive Servo > Page 5828 6. If piston travel is not within specification, select the proper servo assembly (A) one groove, (B) two groove or (C) three groove, to bring the servo piston travel within specification. 7. Remove the dial indicator and servo selection tool. 8. Install the proper reverse band servo spring, reverse band servo piston and rod and reverse band servo cover. 9. Use the (A) Servo Piston Remover/Replacer to install the (B) reverse servo retaining ring. 10. Install the main control valve body. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Page 5829 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > A/T - E4OD New Case And Extension Housing Case: Technical Service Bulletins A/T - E4OD New Case And Extension Housing Article No. 97-23-13 11/10/97 TRANSMISSION - E4OD - NEW DESIGN TRANSMISSION CASE AND EXTENSION HOUSING TRANSMISSIONS BUILT AFTER 7/24/97 LIGHT TRUCK: 1997 ECONOLINE, EXPEDITION, F SUPER DUTY, F-150-350 SERIES 1998 NAVIGATOR ISSUE: A new design transmission case and extension housing has been released. The new design has improved lubrication distribution. ACTION: Refer to the following text for case and extension housing information and new part numbers. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > A/T - E4OD New Case And Extension Housing > Page 5834 The new design case has a plastic lubrication plug in the rear of the case (Figure 1). The new design extension housing has a cast-in shoulder boss (Figure 2) that keeps the lubrication plug in place. The new extension housing must be used with cases that have the lubrication plug. NOTE: DO NOT USE AN EXTENSION HOUSING WITHOUT THE CAST-IN SHOULDER OR BOSS ON ANY CASE HAVING THE LUBRICATION PLUG AS TRANSMISSION DAMAGE MAY RESULT The new design extension housing with the cast-in shoulder or boss will service any E4OD case (past or present). The previous design extension housing without the cast-in shoulder or boss (Figure 2) can only be used on transmission cases built prior to 7/24/97 not having the lubrication plug. CAUTION: BE SURE TO USE ONLY THE NEW DESIGN EXTENSION HOUSING WITH THE TRANSMISSION CASES CONTAINING THE LUBRICATION PLUG. PART NUMBER PART NAME F7TZ-7AO39-AA Extension Housing F7UZ-7A039-BA Extension Housing F85Z-7A039-DA Extension Housing F7UZ-7005-BA Transmission Case F75Z-7005-BB Transmission Case F81Z-7E380-AA Lubrication Plug OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 503000, 504000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > A/T - E4OD New Design Reverse Clutch Assembly Clutch: Technical Service Bulletins A/T - E4OD New Design Reverse Clutch Assembly Article No. 97-17-25 08/18/97 TRANSMISSION - E40D - NEW DESIGN REVERSE CLUTCH ASSEMBLY - TRANSMISSION BUILT FROM 3/26/97 LIGHT TRUCK: 1997 ECONOLINE, EXPEDITION, F-150-350 SERIES 1998 NAVIGATOR ISSUE: A new design reverse clutch assembly for the E4OD transmission has been installed in some 1997 vehicles. This was done to further improve durability and reliability. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > A/T - E4OD New Design Reverse Clutch Assembly > Page 5839 ACTION: Until the new design reverse clutch assembly service parts are fully stocked, the current service parts must be used when replacement of any of the reverse clutch assembly is required (refer to Part Usage Chart and Figure 1). Refer to the following text for details. CAUTION: IF ANY ONE OF THE NEW DESIGN COMPONENTS (REFER TO PART USAGE CHART) REQUIRE REPLACEMENT, ALL FIVE (5) COMPONENTS MUST BE REPLACED. THE PREVIOUS DESIGN AND NEW DESIGN ARE NOT INTERCHANGEABLE ON AN INDIVIDUAL BASIS. When service is required on an E4OD transmission having a build date March 25, 1997 (7C25), or later and is equipped with the new design reverse clutch components, the current level service parts can be used until the new design service parts are available. NOTE: ONLY THE REVERSE CLUTCH COMPONENTS LISTED IN THE PARTS USAGE CHART ARE AFFECTED. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > A/T - E4OD New Design Reverse Clutch Assembly > Page 5840 Follow all the normal service procedures as outlined in the appropriate Service or Workshop Manual. PART NUMBER PART NAME F7TZ-7B067-AC Reverse clutch Hub Assembly F7TZ-7A089-AA Low/Reverse One-Way Clutch F7TZ-7D171-AA One-Way Clutch Inner Race F7TZ-7D006-BA Reverse Planet Assembly (4-Pinion) F7TZ-7B164-AA Reverse Clutch Friction Plates OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 503000, 504000, 590000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > A/T - E4OD New Design Reverse Clutch Assembly > Page 5841 Clutch: Technical Service Bulletins A/T - E4OD Unique Parts Application Article No. 96-21-17 10/07/96 TRANSMISSION - E4OD - UNIQUE OVERDRIVE RING GEAR, ONE-WAY CLUTCH RETAINING RING AND SHAFT RETAINING RING - SERVICE TIP LIGHT TRUCK: 1996 BRONCO 1996-97 ECONOLINE, EXPEDITION, F SUPER DUTY, F-150-350 SERIES This TSB article is being republished in its entirety to revise the applicable models and years. ISSUE: Some 1996 and 1997 vehicles with E4OD transmissions were built with unique overdrive ring gears, one-way clutch retaining ring and center shaft retaining ring (Figure 1). ACTION: If service is required on any of these unique transmissions and replacement of either the overdrive ring gear, one-way clutch retaining ring or center shaft retaining ring is required, all three (3) parts must be replaced. Use current level parts for replacement. PART NUMBER PART NAME E9TZ-7A153-A Overdrive Ring Gear E9TZ-7G375-A Retaining Ring (2 Req'd.) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-6-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 504000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Diagrams > Coast Clutch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Diagrams > Coast Clutch > Page 5844 Clutch: Diagrams Direct Clutch Part 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Diagrams > Coast Clutch > Page 5845 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Diagrams > Coast Clutch > Page 5846 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch Clutch: Service and Repair Direct Clutch Part 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 5849 DISASSEMBLY 1. Remove the ring gear snap ring. 2. Separate the (A) ring gear and (B) output shaft. 3. Remove the (A) output shaft hub snap ring and the (B) output shaft hub. 4. Remove the three output shaft seal rings. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 5850 5. Remove the two direct clutch seal rings. 6. Remove the (A) direct clutch hub and the (B) bearing and direct clutch inner bearing support. 7. Inspect clutch cylinder thrust surfaces, piston bore and clutch plate serrations for scores or burrs. Minor scores or burrs may be removed with crocus cloth. Replace clutch cylinder if badly scored or damaged. 8. Check fluid passage in clutch cylinder for obstructions. Clean out all fluid passages. Inspect clutch piston for scores and replace if necessary. Inspect check balls for freedom of movement and proper seating. 9. Check clutch release spring for distortion and cracks. Replace spring (including wave spring) if distorted or cracked. 10. Inspect composition clutch plates, steel clutch plates and clutch pressure plate for worn or scored bearing surfaces. Replace all parts that are deeply scored or burred. 11. Check clutch plates for flatness and fit on clutch hub serrations. Discard any plate that does not slide freely on serrations or that is not flat. 12. Check clutch hub thrust surfaces for scores and clutch hub splines for wear. 13. Remove the (A) direct clutch pack retaining ring and the (B) direct clutch pack. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 5851 14. Use (A) Clutch Spring Compressor T65L-77515-A to compress the piston return spring and remove the (B) snap ring. 15. Remove the support and spring assembly and piston. WARNING: WEAR SAFETY GLASSES WHEN USING COMPRESSED AIR. NOTE: If necessary, use regulated compressed air (207 kPa [30 psi] max pressure) to remove the clutch piston. 16. Remove the inner piston seal. 17. Remove the outer piston seal. ASSEMBLY Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 5852 1. Position (A) Direct Clutch Lip Seal Protector T80L-77234-A over the clutch cylinder hub and install the (B) inner piston seal. - Install the seal with sealing lip facing down. NOTE: Lubricate direct clutch piston inner seal and seal protector with petroleum jelly. 2. Install the clutch piston outer seal so that when the piston is installed the sealing lip points toward the bottom of the cylinder. 3. Use (A) Direct Clutch Lip Seal Protector T80L-77254-A to install the (B) direct clutch piston. NOTE: Coat inner and outer direct clutch piston seals, clutch cylinder sealing area and piston inner sealing area with petroleum jelly. 4. Install the piston return spring and retainer assembly. 5. Use (A) Clutch Spring Compressor T65L-775 1 5-A to compress the piston return spring and install the (B) retaining ring. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 5853 6. Install the (A) clutch pack and the (B) clutch pack retaining ring. - Alternate external spline (steel) plates and internal spline (friction) plates, starting with a steel plate and ending with the steel pressure plate. NOTE: Before assembly, soak new clutch discs should be soaked in transmission fluid for 15 minutes. 7. Use a (A) feeler gauge to check the clearance between the (B) clutch pack retaining ring and the (C) pressure plate. - If the clearance is not within specifications, install the correct size retaining ring and recheck clearance. 8. Install the washer and the (B) No. 7 needle bearing on the (A) direct clutch hub and install the direct clutch hub. - Install the needle bearing with the black side up, toward direct clutch hub. NOTE: Inspect the output shaft bearing surfaces for scores. Inspect the output shaft splines for wear. Inspect all bushings. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 5854 9. Install the two direct clutch seal rings. CAUTION: Make sure seals are lapped correctly. 10. Install the output shaft hub. (1) Position the output shaft hub. (2) Install the retaining ring. 11. Install the three output shaft seal rings. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 5855 12. Install the No. 8 needle bearing on the direct clutch cylinder. 13. Position the (A) direct clutch on the (B) output shaft. NOTE: Direct clutch cylinder may be installed after the output shaft ring gear is installed to the output shaft hub. 14. Install the ring gear on the output shaft. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 5856 Clutch: Service and Repair Forward Clutch DISASSEMBLY 1. Inspect clutch cylinder thrust surfaces, piston bore and clutch plate serrations for scores or burrs. Minor scores or burrs may be removed with crocus cloth. Replace clutch cylinder if badly scored or damaged. 2. Check fluid passage in clutch cylinder for obstructions. Clean out all fluid passages. Inspect clutch piston for scores and replace if necessary. Inspect check balls for freedom of movement and proper seating. 3. Check clutch release spring for distortion and cracks. Replace spring (including wave spring) if distorted or cracked. 4. Inspect composition clutch plates, steel clutch plates and clutch pressure plate for worn or scored bearing surfaces. Replace all parts that are deeply scored or burred. 5. Check clutch plates for flatness and fit on clutch hub serrations. Discard any plate that does not slide freely on serrations or that is not flat. 6. Check clutch hub thrust surfaces for scores and clutch hub splines for wear. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 5857 7. Remove the (A) forward clutch hub and the (B) No. 3 forward clutch hub front bearing. NOTE: The forward clutch hub may remain in shell during disassembly. 8. Remove the clutch pack selective retaining ring. NOTE: To aid handling, the forward clutch assembly may be set in the extension housing or a hole in the work bench. 9. Remove the (A) pressure plate, (B) clutch pack and (C) pressure spring. 10. Use (A) Direct Clutch Spring Compressor T81P-70235-A and an arbor press to remove the (B) forward clutch retaining ring. CAUTION: Apply only enough pressure to release pressure on the retaining ring. 11. Slowly release the press and remove the forward clutch from the press. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 5858 12. Remove the (A) forward clutch retainer and the (B) return spring. 13. Remove the forward clutch piston. NOTE: Air pressure may be required to remove the forward clutch piston. 14. Remove the (A) inner and (B) outer forward clutch piston seals. 15. Remove the forward clutch input shaft seals. NOTE: The seals are solid seals but will be replaced with scarf cut seals. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 5859 16. Make sure the check ball in the clutch cylinder is free and clean. Check for proper seating. ASSEMBLY 1. Inspect clutch cylinder thrust surfaces, piston bore and clutch plate serrations for scores or burrs. Minor scores or burrs may be removed with crocus cloth. Replace clutch cylinder if badly scored or damaged. 2. Check fluid passage in clutch cylinder for obstructions. Clean out all fluid passages. Inspect clutch piston for scores and replace if necessary. Inspect check balls for freedom of movement and proper seating. 3. Check clutch release spring for distortion and cracks. Replace spring (including wave spring) if distorted or cracked. 4. Inspect composition clutch plates, steel clutch plates and clutch pressure plate for worn or scored bearing surfaces. Replace all parts that are deeply scored or burred. 5. Check clutch plates for flatness and fit on clutch hub serrations. Discard any plate that does not slide freely on serrations or that is not flat. 6. Check clutch hub thrust surfaces for scores and clutch hub splines for wear. NOTE: To aid handling, the forward clutch assembly may be set in the extension housing or a hole in the work bench. 7. Install the (A) inner and (B) outer forward clutch piston seals. Note the direction of the sealing rings before installation. 8. Position (A) Forward Clutch Lip Seal Protector (Inner) T80L-77140-A on the clutch cylinder hub and (B) Forward Clutch Lip Seal Protector (Outer) T68P-7D158-AZ on the clutch piston. NOTE: Coat the piston seals and clutch drum sealing area with petroleum jelly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 5860 9. Install the forward clutch piston into the clutch drum. - Push the piston to the bottom of the drum using even pressure. 10. Position the (A) pressure plate, (B) clutch pack and the (C) piston return spring and retainer. 11. Use (A) Direct Clutch Spring Compressor T81P-70235-A and an arbor press to compress the piston return spring and install the (B) retaining ring. 12. Slowly release the press pressure and remove the forward clutch. 13. Install the clutch pack assembly. (1) Install the pressure ring. (2) Install the clutch pack. (3) Install the pressure plate. NOTE: Before assembly, soak new clutch discs in transmission fluid for 15 minutes. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 5861 14. Install the clutch pack retaining ring. 15. Position and zero Dial Indicator With Bracketry TOOL-4201-C or equivalent on the forward clutch pack. - Push downward on the clutch pack. - Release pressure and zero the dial indicator. 16. Check the clutch pack clearance. (1) Lift up on the clutch pack until it fully seats against the clutch pressure plate retainer. (2) Read the dial indicator. If the clearance is not within specifications, install the correct size retaining ring. Selective Retaining Ring 1.52-1.62 mm (0.060-0.064 inch) 1.87-1.98 mm (0.074-0.078 inch) 2.23-2.69 mm (0.086-0.092 inch) 2.59-2.69 mm (0.102-0.106 inch) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 5862 17. Slide the two scarf-cut seals on the input shaft. (A) is correct; (B) is incorrect mating. NOTE: Make sure scarf-cut seals are mated correctly. 18. Install the two scarf-cut on input shaft. 19. Install the (A) No. 3 forward clutch hub front bearing and the (B) forward clutch hub. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 5863 Clutch: Service and Repair Intermediate Clutch Intermediate Clutch Piston DISASSEMBLY 1. Remove the No. 1 pump support thrust washer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 5864 2. Remove the front pump support. (1) Remove the five bolts. (2) Remove the front pump support. 3. Remove the two (A) reverse clutch cylinder seals and the two (B) forward clutch cylinder seals. NOTE: The reverse clutch cylinder seals are larger than the forward clutch cylinder rings. 4. Remove the (A) inner and (B) outer pump gerotor gears. 5. Carefully pry spring retainer tabs and remove the spring retainer assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 5865 6. Remove the intermediate clutch piston. 7. Remove the (A) intermediate clutch piston inner seal and (B) intermediate clutch piston outer seal. 8. Remove and discard the front pump seal. ASSEMBLY 1. Use (A) Front Pump Seal Replacer T63L-77837-A to install the (B) front pump seal assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 5866 2. Install the (A) intermediate clutch piston inner seal and the (B) intermediate clutch piston outer seal. 3. Install the (A) intermediate clutch piston into (B) Clutch Lip Seal Protector T80L-77005-A. NOTE: Coat the intermediate clutch piston outer seal, intermediate clutch piston inner seal and pump body sealing area with petroleum jelly. 4. Install the intermediate clutch piston. (1) Position the intermediate clutch piston and Clutch Lip Seal Protector T80L-77005-A onto the pump body. (2) Push the intermediate clutch piston to the bottom of the pump body bore by exerting even pressure. 5. Locate the piston bleed hole. CAUTION: The piston bleed hole must be located at 12 o'clock position (towards the top of the transmission). NOTE: The piston bleed hole is the only round hole in the pump body. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 5867 6. Install by snapping the spring retainer assembly on pump body. 7. Install the (A) inner and (B) outer fluid pump gerotor gears. NOTE: The flats on the inner fluid pump gear have steps that must face the pump body for ease of installing the torque converter. 8. Install the (A) reverse clutch cylinder seal and the (B) forward clutch cylinder seals. NOTE: The reverse clutch cylinder seals are larger than the forward clutch cylinder seals. 9. Install new front pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 5868 10. Assemble the front pump. (1) Position the pump support to the pump body assembly. (2) Install the five bolts. Intermediate Clutch Cylinder DISASSEMBLY NOTE: Inspect the outer and inner races for scores or damaged surface areas where rollers contact the races. Inspect the rollers and springs for excessive wear or damage. Inspect the spring and cage for bent or damaged spring retainers. 1. Remove the retaining ring. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 5869 2. Remove the intermediate one-way clutch retainer. 3. Lift and turn counterclockwise to remove intermediate clutch hub. 4. Remove the intermediate one-way clutch. ASSEMBLY 1. Install the intermediate one-way clutch. NOTE: Inspect the outer and inner races for scores or damaged surface areas where rollers contact the races. Inspect the rollers and springs for excessive wear or damage. Inspect the spring and cage for bent or damaged spring retainers. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 5870 2. Install the intermediate clutch hub. NOTE: - For ease of assembly, the chamfer on the intermediate clutch hub splines should face upward. - The clutch hub must rotate counterclockwise when installed on the reverse clutch drum. 3. Install the intermediate one-way clutch retainer. 4. Install the retaining ring. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 5871 Clutch: Service and Repair Reverse Clutch DISASSEMBLY 1. Inspect clutch cylinder thrust surfaces, piston bore and clutch plate serrations for scores or burrs. Minor scores or burrs may be removed with crocus cloth. Replace clutch cylinder if badly scored or damaged. 2. Check fluid passage in clutch cylinder for obstructions. Clean out all fluid passages. Inspect clutch piston for scores and replace if necessary. Inspect check balls for freedom of movement and proper seating. 3. Check clutch release spring for distortion and cracks. Replace spring (including wave spring) if distorted or cracked. 4. Inspect composition clutch plates, steel clutch plates and clutch pressure plate for worn or scored bearing surfaces. Replace all parts that are deeply scored or burred. 5. Check clutch plates for flatness and fit on clutch hub serrations. Discard any plate that does not slide freely on serrations or that is not flat. 6. Check clutch hub thrust surfaces for scores and clutch hub splines for wear. 7. Remove the No. 2 forward clutch bearing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 5872 8. Remove the reverse clutch pressure plate retainer. 9. Remove the reverse clutch pack. 10. Use (A) Reverse Clutch Spring Compressor T80L-77405-A and (B) Clutch Spring Compressor T65L-77515-A to compress the (C) reverse clutch piston spring. 11. Remove the reverse clutch piston spring retaining ring. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 5873 12. Remove the (A) reverse clutch piston spring and the (B) reverse clutch piston spring pressure ring. 13. Remove the reverse clutch piston. NOTE: To ease reverse clutch piston removal, it may be necessary to apply air pressure to the reverse clutch drum. Block the opposite hole. 14. Remove the (A) reverse clutch piston inner seal and the (B) reverse clutch piston outer seal. ASSEMBLY 1. Inspect clutch cylinder thrust surfaces, piston bore and clutch plate serrations for scores or burrs. Minor scores or burrs may be removed with crocus cloth. Replace clutch cylinder if badly scored or damaged. 2. Check fluid passage in clutch cylinder for obstructions. Clean out all fluid passages. Inspect clutch piston for scores and replace if necessary. Inspect check balls for freedom of movement and proper seating. 3. Check clutch release spring for distortion and cracks. Replace spring (including wave spring) if distorted or cracked. 4. Inspect composition clutch plates, steel clutch plates and clutch pressure plate for worn or scored bearing surfaces. Replace all parts that are deeply scored or burred. 5. Check clutch plates for flatness and fit on clutch hub serrations. Discard any plate that does not slide freely on serrations or that is not flat. 6. Check clutch hub thrust surfaces for scores and clutch hub splines for wear. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 5874 7. Install a new (A) reverse clutch piston inner seal and (B) reverse clutch piston outer seal. NOTE: The piston check ball must be present and moving freely. 8. Install the reverse clutch piston. (1) Position Reverse Clutch Inner Seal Protector T80L-77403-B on the clutch hub. (2) Place Reverse Clutch Outer Seal Protector T80L-77403-A over reverse clutch piston. (3) Position the reverse clutch piston and use even pressure to push it to the bottom of the reverse clutch drum. NOTE: Coat the reverse clutch piston inner seal, reverse clutch piston outer seal reverse clutch drum sealing area and seal protector with petroleum jelly. 9. Install the (A) pressure ring and the (B) reverse clutch piston spring. NOTE: The dished side of the reverse clutch piston spring must face the reverse clutch piston. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 5875 10. Use (A) Reverse Clutch Spring Compressor T80L-77405-A and (B) Clutch Spring Compressor T65L-77515-A to compress the (C) reverse clutch piston spring. 11. Install the reverse clutch piston spring retaining ring. 12. Remove Reverse Clutch Spring Compressor T80L-77405-A and Clutch Spring Compressor T65L-77515-A. 13. Install the reverse clutch front pressure plate, clutch pack and reverse clutch rear pressure plate. NOTE: - Before assembly, soak new clutch discs in transmission fluid for 15 minutes. - Install the pressure plates with the flat sides facing the clutch pack. 14. Install the reverse clutch pressure plate retainer snap ring. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 5876 15. Position and zero Dial Indicator With Bracketry TOOL-4201-C on the reverse clutch pack. - Push downward on the clutch pack. - Release pressure and zero the dial indicator. 16. Check the reverse clutch pack clearance. (1) Lift up on the clutch pack until it fully seats against the reverse clutch pressure plate retainer. (2) Read the dial indicator. - If clearance is not within specifications, install the correct size retaining ring. Selective Retaining Rings 1.52-1.62 mm (0.060-0.064 inch) 1.87-1.98 mm (0.074-0.078 inch) 2.23-2.33 mm (0.088-0.092 inch) 259-2.69 mm (0.102-0.106 inch) 17. Check the clutch for proper operation. Apply air pressure to the reverse clutch drum. The clutch should be heard and felt to work without leakage. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Tools and Equipment > Forward Clutch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Tools and Equipment > Forward Clutch > Page 5879 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Technical Service Bulletins > A/T - E4OD New Case And Extension Housing Extension Housing: Technical Service Bulletins A/T - E4OD New Case And Extension Housing Article No. 97-23-13 11/10/97 TRANSMISSION - E4OD - NEW DESIGN TRANSMISSION CASE AND EXTENSION HOUSING TRANSMISSIONS BUILT AFTER 7/24/97 LIGHT TRUCK: 1997 ECONOLINE, EXPEDITION, F SUPER DUTY, F-150-350 SERIES 1998 NAVIGATOR ISSUE: A new design transmission case and extension housing has been released. The new design has improved lubrication distribution. ACTION: Refer to the following text for case and extension housing information and new part numbers. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Technical Service Bulletins > A/T - E4OD New Case And Extension Housing > Page 5884 The new design case has a plastic lubrication plug in the rear of the case (Figure 1). The new design extension housing has a cast-in shoulder boss (Figure 2) that keeps the lubrication plug in place. The new extension housing must be used with cases that have the lubrication plug. NOTE: DO NOT USE AN EXTENSION HOUSING WITHOUT THE CAST-IN SHOULDER OR BOSS ON ANY CASE HAVING THE LUBRICATION PLUG AS TRANSMISSION DAMAGE MAY RESULT The new design extension housing with the cast-in shoulder or boss will service any E4OD case (past or present). The previous design extension housing without the cast-in shoulder or boss (Figure 2) can only be used on transmission cases built prior to 7/24/97 not having the lubrication plug. CAUTION: BE SURE TO USE ONLY THE NEW DESIGN EXTENSION HOUSING WITH THE TRANSMISSION CASES CONTAINING THE LUBRICATION PLUG. PART NUMBER PART NAME F7TZ-7AO39-AA Extension Housing F7UZ-7A039-BA Extension Housing F85Z-7A039-DA Extension Housing F7UZ-7005-BA Transmission Case F75Z-7005-BB Transmission Case F81Z-7E380-AA Lubrication Plug OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 503000, 504000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Technical Service Bulletins > Page 5885 Extension Housing: Specifications TORQUE SPECIFICATIONS Extension Housing Bolts ............................................................................................................................................................ 25-30 Nm (18-22 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage Fluid - A/T: Technical Service Bulletins A/T - Mercon V ATF Usage TSB 06-14-4 07/24/06 MERCON ATF IS BEING REPLACED BY MERCON V ATF AS A SERVICE FLUID. FORD: 1980-1997 Crown Victoria 1981-1997 Mustang, Thunderbird 1981-2003 Escort 1986-1993 Festiva 1986-1997 Taurus 1989-1997 Probe 1994-1997 Aspire 1995-2000 Contour 1980-1996 Bronco 1981-2003 F-150 1981-2004 E-Series, F-Super Duty 1983-1996 Ranger 1986-1996 Aerostar 1991-1997 Explorer 1993-2004 F-53 Motorhome Chassis 1995-1998 Windstar 1997-2004 Expedition 2000-2005 Excursion 2001-2007 Escape 1987-2000 F-B-Series 2000-2007 F-650, F-750 LINCOLN: 1980-1997 Town Car 1981-1997 Continental 1993-1997 Mark VIII 1998-2004 Navigator 2002-2003 Blackwood MERCURY: 1980-1997 Grand Marquis 1981-1997 Cougar 1986-1997 Sable 1987-1999 Tracer 1995-2000 Mystique 1999-2002 Cougar 1993-2002 Villager 1997 Mountaineer 2005-2007 Mariner MERKUR: 1985-1989 XR4TI This article supersedes TSB 01-15-7 to update the vehicle application chart. ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid. ACTION Beginning immediately all automatic transmission / transaxle applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will only continue for however long it takes to deplete what remains in inventory. SERVICE PROCEDURE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage > Page 5890 Service automatic transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V For proper fluid application on current and past model vehicles equipped with automatic transmissions I transaxles refer to the fluid usage chart. (Figure 1) CAUTION AUTOMATIC TRANSMISSIONS / TRANSAXLES THAT REQUIRE MERCON® V SHOULD STILL ONLY USE MERCON(R) V OR DUAL USAGE FLUID LABELED MERCON(R) / MERCON(R) V. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage > Page 5891 CAUTION MERCON(R) SP, MOTORCRAFT PREMIUM AUTOMATIC TRANSMISSION FLUID AND MOTORCRAFT M5 ATFS ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR TRANSMISSION DAMAGE. CAUTION THE FUNCTIONAL CHARACTERISTICS OF FLUIDS FOR CVT TRANSMISSIONS ARE VERY DIFFERENT THAN THOSE OF OTHER AUTOMATIC TRANSMISSION FLUIDS (ATFS). USE OF A FLUID OTHER THAN MOTORCRAFT CONTINUOUSLY VARIABLE CHAIN TYPE TRANSMISSION FLUID OR ONE LABELED AS MEETING MERCON(R) C WILL CAUSE FUNCTIONALITY CONCERNS AND INTERNAL TRANSMISSION DAMAGE. CAUTION DO NOT USE AUTOMATIC TRANSMISSION FLUID SUPPLEMENTS, ADDITIVES, TREATMENTS OR CLEANING AGENTS. Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications With E4OD Transmission A/T Fluid Capacity ............................................................................................................................... ......................................................... 13.2L (13.9 Qt) A/T Fluid Refill ..................................................................................................................................... ............................................................ 4.7L (5.0 Qt) NOTE: With engine at operating temperature, shift through all gears. Check fluid in PARK add fluid as needed. With 4R70W Transmission A/T Fluid .............................................................................................................................................. ............................................................. 4.7L (5.0 Qt) Initial refill. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 5894 Fluid - A/T: Fluid Type Specifications NOTE: MERCON Automatic Transmission Fluid is being replaced by MERCON V as a service fluid. Automatic (4R70W) ............................................................................................................................. ..................................................... MERCON V ATF Automatic (4R100) ............................................................................................................................................................. MERCON or MERCON V ATF Automatic (E40D) ............................................................................................................................................................. MERCON or MERCON V ATF NOTE: Automatic transmissions requiring MERCON V should only be serviced with MERCON V, or fluid from a container that is specified as a dual usage fluid: MERCON/MERCON V. NOTE: Automatic transmissions requiring MERCON can not be serviced with MERCON, MERCON V, or dual usage fluids labeled MERCON/MERCON V. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5895 Fluid - A/T: Diagrams PARK Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5896 PARK Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5897 PARK Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5898 PARK Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5899 2 ND GEAR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5900 2 ND GEAR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5901 TCC RELEASE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5902 TCC RELEASE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5903 LINE/SRV PRESSURE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5904 PARK NON-PTO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5905 PARK NON-PTO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5906 1ST GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5907 2ND GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5908 3RD GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5909 4TH GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5910 MANUAL 3RD GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5911 MANUAL 2ND GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5912 MANUAL 1ST GEAR NON-PTO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > Condition Fluid - A/T: Testing and Inspection Condition 1. Perform the fluid level check. 2. Observe the color and odor of the fluid. It should be dark reddish, not brown or black. Odor can sometimes indicate that there is an overheating condition clutch disc failure or band failure. 3. Use an absorbent white facial tissue to wipe the fluid level indicator. Examine the stain for evidence of solids (specks of any kind) and for signs of antifreeze (gum or varnish on the fluid level indicator). If specks are present in the fluid or there is evidence of antifreeze, the transmission fluid pan must be removed for further inspection. If fluid contamination or transmission failure is confirmed by further evidence of coolant or excessive solids in the transmission fluid pan, the transmission must be disassembled and completely cleaned and serviced. This includes cleaning the torque converter and transmission cooling system. Do not perform any further checks before cleaning and servicing the transmission. During disassembly and assembly, all overhaul checks and adjustments of clearances and end play must be made. After the transmission has been serviced, all diagnostic tests and adjustments listed in the Diagnosis by Symptom chart must be completed to ensure the concern has been corrected. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > Condition > Page 5915 Fluid - A/T: Testing and Inspection Level Check CAUTION: - The vehicle should not be driven if the fluid level is below the COLD marked area on the fluid level indicator and outside temperature is above 10° C (50° F). - If vehicle has been operated for an extended period at high speed, in city traffic, in hot weather, or vehicle is being used to pull a trailer, the fluid has to cool approximately 30 minutes after engine had been turned off to obtain an accurate reading. Under normal circumstances, check the fluid level of the transmission during normal maintenance, and change it at 48,000 km (30,000 miles) since the vehicle does not use up transmission fluid. However, if the transmission is not working properly, the transmission may slip or shift slowly or there may be some sign of fluid leakage. The fluid level should he checked It is preferable to check the transmission fluid level at normal operating temperature after approximately 32 km (20 miles) of driving. If necessary, check the fluid level without driving the vehicle, if the outside temperature is above 10° C (50° F). When checking fluid at normal operating temperature, the fluid level should be within the HOT marked area on the fluid level indicator. When the vehicle has not been driven and outside temperature is above 10° C (50° F), the fluid level should be within the COLD marked area on the fluid level indicator. Check Fluid Level as Follows: NOTE:The fluid level on the fluid level indicator will be different at operating temperature and ambient temperature. For the correct fluid level reading on the fluid level indicator, follow the appropriate instructions. 1. With the transmission in Park (P), the engine at curb idle rpm, the foot brakes applied and the vehicle on a level surface, move the transmission range selector lever through each range. Allow time in each range to engage the transmission. Return to Park (P), apply the parking brake and block the wheels. Do not turn off the engine during the fluid level check. 2. Clean all dirt from the transmission fluid level indicator cap before removing the fluid level indicator from the fluid fill tube. 3. Pull the fluid level indicator out of the fluid fill tube, wipe it clean, and push it all the way back into the tube. Make sure it is fully seated. 4. Pull the fluid level indicator out of the fluid fill tube again and check the fluid level. If necessary, add enough fluid through the transmission fluid fill tube to raise the level to the correct position. Do not overfill the transmission. This will result in foaming, loss of fluid through the vent and possible transmission malfunction. If overfill occurs, excess fluid must be removed. 5. Install the fluid level indicator, making sure it is fully seated in the fluid fill tube. If the transmission fluid level is checked when the fluid is at ambient temperature, the fluid level indicator could indicate that fluid should be added if the fluid level indicator is misread. If fluid is added at this time, an overfill condition could result when the fluid reaches operating temperatures of 66° C-77° C (150° F-170° F) (fluid level indicator hot to touch). Underfill can result in transmission loss of engagement or slipping. This condition is most evident in cold weather or when the vehicle is parked or being driven on a hill. If the transmission fluid level is correctly established at 10-35° C (50-95° F), it will appear in the HOT marked area on the fluid level indicator when the transmission reaches an operating temperature of 66-77° C (150-170° F). Do not overfill or underfill. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > E4OD Fluid - A/T: Service and Repair E4OD NOTE: MERCON Automatic Transmission Fluid is being replaced by MERCON V as a service fluid. A fluid level that is too high may cause the fluid to become aerated due to the churning action of the rotating parts of the transmission. Aerated fluid will cause erratic control pressure, and the aerated fluid may be forced from the vent. A fluid level that is too low will affect transmission operation. Low fluid level may indicate fluid leaks that may cause transmission damage. CAUTION: Use of any fluid other than specified could result in transmission malfunction or failure. Use only Motorcraft MERCON or MERCON V Automatic Transmission Fluid or equivalent in all Ford automatic transmissions. Before adding any fluid, make sure the correct type will be used. Add fluid in 0.24 L (0.5 pint) increments through the fluid filler tube to bring the level to the correct area on the fluid level indicator. If an overfill occurs, remove excess fluid. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > E4OD > Page 5918 Fluid - A/T: Service and Repair 4R70W Adding Fluid NOTE: MERCON Automatic Transmission Fluid is being replaced by MERCON V as a service fluid. A fluid level that is too high may cause the fluid to become aerated due to the churning action of the rotating parts of the transmission. Aerated fluid will cause erratic control pressure, and the aerated fluid may be forced from the vent. A fluid level that is too low will affect transmission operation. Low fluid level may indicate fluid leaks that may cause transmission damage. CAUTION: Use of any fluid other than specified could result in transmission malfunction or failure. Use only Motorcraft MERCON or MERCON V Automatic Transmission Fluid or equivalent meeting FORD specification. Before adding any fluid, make sure the correct type will be used. Add fluid in 0.24 L (0.5 pint) increments through the fluid filler tube to bring the level to the correct area on the fluid level indicator. If an overfill occurs, remove excess fluid. Partial Drain and Refill NOTE: MERCON Automatic Transmission Fluid is being replaced by MERCON V as a service fluid. Normal maintenance requires periodic automatic transmission fluid changes. If a major service, such as a clutch, band, bearing, etc., is required, the automatic transmission fluid will also have to be removed for service. At this time, the torque converter, transmission cooler, cooler inlet tube and cooler tube must be thoroughly flushed to remove any dirt. When used under continuous or severe conditions, the transmission and torque converter should be drained and refilled with fluid as specified. Normal Maintenance Change fluid at 48,279 km (30,000 miles). Severe Duty/Major Overhaul Change fluid at 33,795 km (21,000 miles). CAUTION: Use of a fluid other than specified could result in transmission malfunction and/or failure. Refer to the vehicle certification label affixed to the LH front door lock face panel or door pillar for the transmission code. Procedures for partial drain and refill are as follows: 1. Raise vehicle on a hoist and position suitable safety stands under vehicle. WARNING: The electrical power to the air suspension system must be shut OFF prior to hoisting, jacking or towing an air suspension vehiclE. This can be accomplished by turning OFF the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. 2. Place drain pan under transmission. 3. Loosen transmission pan retaining bolts and allow fluid to drain from transmission. 4. When fluid has drained to level of pan flange, remove the transmission pan retaining bolts working from the right-hand side of the transmission. Carefully lower the transmission pan and drain remaining fluid. 5. Remove the pan to case gasket and thoroughly clean the transmission pan and pan magnet. 6. Drain the torque converter by removing the torque converter drain plug. 7. Thoroughly flush torque converter, auxiliary fluid cooler and lines. 8. After torque converter has been drained, install new torque converter drain plug. 9. Replace transmission fluid filter and seal as required. CAUTION: If replacing the filter and the seal remains in main control bore, carefully use a small screwdriver to remove it. Take care not to damage main control bore. NOTE: If servicing for contamination-related failure, use a new filter and seal. Filter may be reused if no excessive contamination is present. 10. Clean and inspect transmission pan to case gasket. If OK, reuse. Install pan to case gasket on transmission pan. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > E4OD > Page 5919 11. Install pan magnet in transmission pan. Install transmission pan to transmission. Tighten fourteen retaining bolts to proper torque. 12. Remove safety stands and lower vehicle. NOTE: If equipped with air suspension, reactivate the system by turning ON the air suspension switch. 13. When filling a dry transmission and converter, start with a minimum of 4.7 liters (5 quarts). 14. Fill transmission to proper level with Motorcraft MERCON or MERCON V Automatic Transmission Fluid or equivalent meeting FORD specification. Total Drain and Refill NOTE: MERCON Automatic Transmission Fluid is being replaced by MERCON V as a service fluid. REMOVAL 1. Raise and support the vehicle. WARNING: The electrical power to the air suspension system must be shut OFF prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning OFF the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. 2. Place a drain pan under the transmission fluid pan. 3. Drain the transmission fluid. - Loosen the transmission fluid pan bolts and allow the fluid to drain. After the fluid is drained remove the bolts. 4. Remove the (A) transmission fluid pan and the (B) transmission pan gasket. - Replace transmission pan gasket as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > E4OD > Page 5920 5. Pull down evenly and remove the transmission fluid filter, seal and filter kit. 6. Remove the converter housing access plug. 7. Remove the torque converter drain plug and drain the torque converter. - Rotate the crankshaft to access the drain plug. 8. Clean and inspect the (A) transmission fluid pan, the (B)pan gasket and the (C) magnet. 9. Flush the torque converter, cooler, and cooler lines. INSTALLATION 1. Install the new torque converter drain plug. NOTE: A new torque converter drain plug must be installed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > E4OD > Page 5921 2. Install the converter housing access plug. CAUTION: If replacing the filter, and the seal remains in the main control bore, carefully use a small screwdriver to remove the seal. Use care not to damage the main control bore. NOTE: If the transmission is being repaired for a contamination-related failure, use a new filter and seal. The filter may be reused if no excessive contamination is present. 3. Replace the fluid filter and seal as required. 4. Position the pan magnet into the transmission fluid pan. 5. Install the transmission fluid pan and gasket. (1) Position the transmission pan gasket. (2) Position the transmission fluid pan. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > E4OD > Page 5922 NOTE: The transmission pan gasket is reusable. Clean and inspect for damage; if not damaged, reuse the gasket. 6. Install the transmission fluid pan bolts. 7. Remove the supports and lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning ON the air suspension switch. 8. Fill the transmission to the proper fluid level. - Use Motorcraft MERCON or MERCON V Automatic Transmission Fluid or equivalent meeting FORD specification. NOTE: When filling a dry transmission and converter start with a minimum of 4.7 liters (5 quarts). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 97-24-23 > Nov > 97 > Engine - Stall During Transmission Engagement Fluid Filter - A/T: Customer Interest Engine - Stall During Transmission Engagement Article No. 97-24-23 11/24/97 ^ STALL - ENGINE STALL DURING TRANSMISSION ENGAGEMENT - VEHICLES EQUIPPED WITH E4OD TRANSMISSION ^ TRANSMISSION - E4OD - ENGINE STALL DURING ENGAGEMENT LIGHT TRUCK: 1996 BRONCO 1996-97 ECONOLINE, F-150-350 SERIES, F-53 MOTORHOME 1997 EXPEDITION 1998 NAVIGATOR This TSB article is being republished in its entirety to revise the Service Procedure. ISSUE: Some vehicles may stall when the transmission is placed into gear. This may be caused by the transmission fluid filter becoming detached and/or loose. ACTION: Install a new design fluid filter and seal assembly. The new design has legs molded into the plastic filter cover (Figure 1). This new design filter does not require using the rectangular transmission pan magnet. SERVICE PROCEDURE Follow all the normal diagnostic procedures outlined in the appropriate model/year Service Manual. Repair as required. If all normal diagnostics fail to correct the problem, refer to the following Steps. 1. Remove the transmission fluid pan to determine if the transmission fluid filter has dropped down or is not firmly seated in the pump bore. 2. If the filter has dropped down into the pan, discard the filter assembly and remove the filter seal from the pump bore. CAUTION: BE CAREFUL NOT TO SCRATCH OR DAMAGE THE PUMP BORE WHEN REMOVING THE SEAL. NOTE: DO NOT REMOVE THE ORIGINAL FLUID PAN MAGNET FROM THE FLUID PAN OTHER THAN TO CLEAN AND REINSTALL. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 97-24-23 > Nov > 97 > Engine - Stall During Transmission Engagement > Page 5931 3. Install a new Filter and Seal Assembly (F6TZ-7A098-AB: 4X2, F6TZ-7A098-BB: 4X4). Refer to Figure 1. CAUTION: DO NOT USE THE RECTANGULAR TRANSMISSION PAN MAGNET WHEN USING EITHER OF THESE NEW DESIGN FILTER AND SEAL ASSEMBLIES. CAUTION: DO NOT REPLACE A REUSABLE PAN GASKET WITH A CORK GASKET, THIS MAY RESULT IN A TRANSMISSION FLUID LEAK. CLEAN AND REUSE UNLESS DAMAGED. REPLACE CORK GASKET WITH CORK GASKETS. 4. Refill transmission as required using MERCON(R) Multi-Purpose Automatic Transmission Fluid (ATF) (XT-2-QDX). PART NUMBER PART NAME F6TZ-7A098-AB Filter And Seal Assembly (4X2) F6TZ-7A098-BB Filter And Seal Assembly (4X4) XT-2-QDX MERCON(R) Multi-Purpose Automatic Transmission Fluid (ATF) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-18-7 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 972423A Remove And Install Pan 0.7 Hr. To Replace Filter And Seal Assembly 972423B Additional Time To Clean, 0.1 Hr. Inspect, And Reuse Elastomeric Reusable Pan Gasket DEALER CODING CONDITION BASIC PART NO. CODE 7A098 33 OASIS CODES: 503000, 504000, 607000, 607400 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 97-15-21 > Jul > 97 > Engine - Stalls When Transmission is Engaged Fluid Filter - A/T: Customer Interest Engine - Stalls When Transmission is Engaged Article No. 97-15-21 07/21/97 ^ STALL - ENGINE STALL DURING TRANSMISSION ENGAGEMENT - VEHICLES EQUIPPED WITH E40D TRANSMISSION ^ TRANSMISSION - E4OD - ENGINE STALL DURING ENGAGEMENT LIGHT TRUCK: 1996 BRONCO 1996-97 ECONOLINE, F-150-350 SERIES, F-53 MOTORHOME CHASSIS 1997 EXPEDITION 1998 NAVIGATOR ISSUE: Some vehicles may stall when the transmission is placed into gear. This may be caused by the transmission fluid filter becoming detached and/or loose. ACTION: Install a rectangular fluid pan magnet under the transmission fluid filter to keep the filter in place and reduce the possibility of the filter becoming loose. Refer to the following Service Procedure for details. SERVICE PROCEDURE Follow all the normal diagnostic procedures outlined in the appropriate model/year Service Manual. Repair as required. If all normal diagnostics fail to correct the problem, refer to the following Steps. 1. Remove the transmission fluid pan to determine if the transmission fluid filter has dropped down or is not firmly seated in the pump bore. 2. If the filter is not firmly seated in the pump bore or falls down into the fluid pan when the pan is removed, place the rectangular Transmission Pan Magnet (F3RZ-7E290-AC) on the pan at the location shown in Figure 1. NOTE: DO NOT REMOVE THE ORIGINAL FLUID PAN MAGNET FROM THE FLUID PAN OTHER THAN TO CLEAN AND REINSTALL. CAUTION: DO NOT USE THE ORIGINAL FLUID PAN MAGNET TO HOLD THE FILTER IN PLACE. IT IS TOO THICK AND MAY CAUSE A LEAK. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 97-15-21 > Jul > 97 > Engine - Stalls When Transmission is Engaged > Page 5936 3. Install a new Filter and Seal Assembly (E9TZ-7A098-A). CAUTION: DO NOT REMOVE AND REPLACE THE REUSABLE PAN GASKET OR REPLACE IT WITH A CORK GASKET, THIS MAY RESULT IN A LEAK CONDITION. 4. Refill transmission as required using MERCON(R) Multi-Purpose Automatic Transmission Fluid (ATF) (XT-2-ODX). PART NUMBER PART NAME F3PZ-E290-AC Transmission Pan Magnet XT-2-ODX MERCON(R) Multi-Purpose Automatic Transmission Fluid (ATF) E9TZ-7A098-A Filter And Seal Assembly OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971521A Install New Pan Magnet 0.7 Hr. 971521B Additional Time To Clean, 0.1 Hr. Inspect, And Reuse Elastomeric Reusable Pan Gasket DEALER CODING CONDITION BASIC PART NO. CODE 7A098 33 OASIS CODES: 502000, 503000, 504000, 607000, 607400 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 97-24-23 > Nov > 97 > Engine Stall During Transmission Engagement Fluid Filter - A/T: All Technical Service Bulletins Engine - Stall During Transmission Engagement Article No. 97-24-23 11/24/97 ^ STALL - ENGINE STALL DURING TRANSMISSION ENGAGEMENT - VEHICLES EQUIPPED WITH E4OD TRANSMISSION ^ TRANSMISSION - E4OD - ENGINE STALL DURING ENGAGEMENT LIGHT TRUCK: 1996 BRONCO 1996-97 ECONOLINE, F-150-350 SERIES, F-53 MOTORHOME 1997 EXPEDITION 1998 NAVIGATOR This TSB article is being republished in its entirety to revise the Service Procedure. ISSUE: Some vehicles may stall when the transmission is placed into gear. This may be caused by the transmission fluid filter becoming detached and/or loose. ACTION: Install a new design fluid filter and seal assembly. The new design has legs molded into the plastic filter cover (Figure 1). This new design filter does not require using the rectangular transmission pan magnet. SERVICE PROCEDURE Follow all the normal diagnostic procedures outlined in the appropriate model/year Service Manual. Repair as required. If all normal diagnostics fail to correct the problem, refer to the following Steps. 1. Remove the transmission fluid pan to determine if the transmission fluid filter has dropped down or is not firmly seated in the pump bore. 2. If the filter has dropped down into the pan, discard the filter assembly and remove the filter seal from the pump bore. CAUTION: BE CAREFUL NOT TO SCRATCH OR DAMAGE THE PUMP BORE WHEN REMOVING THE SEAL. NOTE: DO NOT REMOVE THE ORIGINAL FLUID PAN MAGNET FROM THE FLUID PAN OTHER THAN TO CLEAN AND REINSTALL. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 97-24-23 > Nov > 97 > Engine Stall During Transmission Engagement > Page 5942 3. Install a new Filter and Seal Assembly (F6TZ-7A098-AB: 4X2, F6TZ-7A098-BB: 4X4). Refer to Figure 1. CAUTION: DO NOT USE THE RECTANGULAR TRANSMISSION PAN MAGNET WHEN USING EITHER OF THESE NEW DESIGN FILTER AND SEAL ASSEMBLIES. CAUTION: DO NOT REPLACE A REUSABLE PAN GASKET WITH A CORK GASKET, THIS MAY RESULT IN A TRANSMISSION FLUID LEAK. CLEAN AND REUSE UNLESS DAMAGED. REPLACE CORK GASKET WITH CORK GASKETS. 4. Refill transmission as required using MERCON(R) Multi-Purpose Automatic Transmission Fluid (ATF) (XT-2-QDX). PART NUMBER PART NAME F6TZ-7A098-AB Filter And Seal Assembly (4X2) F6TZ-7A098-BB Filter And Seal Assembly (4X4) XT-2-QDX MERCON(R) Multi-Purpose Automatic Transmission Fluid (ATF) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-18-7 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 972423A Remove And Install Pan 0.7 Hr. To Replace Filter And Seal Assembly 972423B Additional Time To Clean, 0.1 Hr. Inspect, And Reuse Elastomeric Reusable Pan Gasket DEALER CODING CONDITION BASIC PART NO. CODE 7A098 33 OASIS CODES: 503000, 504000, 607000, 607400 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 97-15-21 > Jul > 97 > Engine Stalls When Transmission is Engaged Fluid Filter - A/T: All Technical Service Bulletins Engine - Stalls When Transmission is Engaged Article No. 97-15-21 07/21/97 ^ STALL - ENGINE STALL DURING TRANSMISSION ENGAGEMENT - VEHICLES EQUIPPED WITH E40D TRANSMISSION ^ TRANSMISSION - E4OD - ENGINE STALL DURING ENGAGEMENT LIGHT TRUCK: 1996 BRONCO 1996-97 ECONOLINE, F-150-350 SERIES, F-53 MOTORHOME CHASSIS 1997 EXPEDITION 1998 NAVIGATOR ISSUE: Some vehicles may stall when the transmission is placed into gear. This may be caused by the transmission fluid filter becoming detached and/or loose. ACTION: Install a rectangular fluid pan magnet under the transmission fluid filter to keep the filter in place and reduce the possibility of the filter becoming loose. Refer to the following Service Procedure for details. SERVICE PROCEDURE Follow all the normal diagnostic procedures outlined in the appropriate model/year Service Manual. Repair as required. If all normal diagnostics fail to correct the problem, refer to the following Steps. 1. Remove the transmission fluid pan to determine if the transmission fluid filter has dropped down or is not firmly seated in the pump bore. 2. If the filter is not firmly seated in the pump bore or falls down into the fluid pan when the pan is removed, place the rectangular Transmission Pan Magnet (F3RZ-7E290-AC) on the pan at the location shown in Figure 1. NOTE: DO NOT REMOVE THE ORIGINAL FLUID PAN MAGNET FROM THE FLUID PAN OTHER THAN TO CLEAN AND REINSTALL. CAUTION: DO NOT USE THE ORIGINAL FLUID PAN MAGNET TO HOLD THE FILTER IN PLACE. IT IS TOO THICK AND MAY CAUSE A LEAK. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 97-15-21 > Jul > 97 > Engine Stalls When Transmission is Engaged > Page 5947 3. Install a new Filter and Seal Assembly (E9TZ-7A098-A). CAUTION: DO NOT REMOVE AND REPLACE THE REUSABLE PAN GASKET OR REPLACE IT WITH A CORK GASKET, THIS MAY RESULT IN A LEAK CONDITION. 4. Refill transmission as required using MERCON(R) Multi-Purpose Automatic Transmission Fluid (ATF) (XT-2-ODX). PART NUMBER PART NAME F3PZ-E290-AC Transmission Pan Magnet XT-2-ODX MERCON(R) Multi-Purpose Automatic Transmission Fluid (ATF) E9TZ-7A098-A Filter And Seal Assembly OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971521A Install New Pan Magnet 0.7 Hr. 971521B Additional Time To Clean, 0.1 Hr. Inspect, And Reuse Elastomeric Reusable Pan Gasket DEALER CODING CONDITION BASIC PART NO. CODE 7A098 33 OASIS CODES: 502000, 503000, 504000, 607000, 607400 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 98-20-19 > Oct > 98 > Power Seat Switch - Button Comes Off Power Seat Switch: All Technical Service Bulletins Power Seat Switch - Button Comes Off Article No. 98-20-19 10/12/98 POWER SEAT SWITCH - BUTTON COMES OFF LIGHT TRUCK: 1995-99 EXPLORER 1997-99 ECONOLINE, EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE The power seat control button (knob) may detach from the switch actuator. This may be due to insufficient adhesion between the button and the switch actuator. ACTION Attach a new button and use an adhesive to reduce the possibility of the button detaching from the actuator. The button was not previously adhered. This revised process has been tested for shear and pull strengths. Refer to the following text for details. Refer to the Instruction Sheet included with Knob Kit (F85Z-14711-AA). Ford Instant Adhesive (E8AZ-19554-A) or equivalent meeting Ford specification WSK-M2G402-A4 is not included with the kit, but is required to complete this repair procedure. Order Ford Instant Adhesive separately. PART NUMBER PART NAME F85Z-14711-AA Knob Kit E8AZ-l9554-A Instant Adhesive OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982019A Install Power Seat Control 0.2 Hr. Button DEALER CODING CONDITION BASIC PART NO. CODE 14711 68 OASIS CODES: 101000, 107000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Page 5958 Fluid Filter - A/T: Service and Repair NOTE: MERCON Automatic Transmission Fluid is being replaced by MERCON V as a service fluid. REMOVAL 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Place a drain pan under the transmission fluid pan. 3. Drain the transmission fluid. - Loosen the transmission fluid pan bolts and allow the fluid to drain. After the fluid is drained remove the bolts. 4. Remove the (A) transmission fluid pan and the (B) transmission pan gasket. 5. Pull down evenly and remove the transmission fluid filter and seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Page 5959 6. Remove the converter housing access plug. 7. Remove the torque converter drain plug and drain the torque converter. - Rotate the crankshaft to access the drain plug. 8. Clean and inspect the (A) transmission fluid pan, the (B) transmission pan gasket and the (C) magnet. 9. Flush the torque converter, cooler, and cooler lines. INSTALLATION 1. Install the new torque converter drain plug. NOTE: A new torque converter drain plug must be installed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Page 5960 2. Install the converter housing access plug. 3. Replace the fluid filter and seal as required. CAUTION: If replacing the filter, and the seal remains in the main control bore, carefully use a small screwdriver to remove the seal. Use care not to damage the main control bore. NOTE: If the transmission is being repaired for a contamination-related failure, use a new filter and seal. The filter may be reused if no excessive contamination is present. 4. Position the pan magnet into the transmission fluid pan. 5. Install the transmission fluid pan and gasket. (1) Position the transmission pan gasket. (2) Position the transmission fluid pan. NOTE: The transmission pan gasket is reusable. Clean and inspect for damage; if not damaged, reuse the gasket. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Page 5961 6. Install the transmission fluid pan bolts. 7. Remove supports and lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. 8. Fill the transmission to the proper fluid level. - Use Motorcraft MERCON or MERCON V Automatic Transmission Fluid or equivalent meeting FORD specification. NOTE: When filling a dry transmission and converter start with a minimum of 4.7 liters (5 quarts). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Torque Converter - Cleaning and Replacement Guidelines Technical Service Bulletin # 962612 Date: 961216 Torque Converter - Cleaning and Replacement Guidelines Article No. 96-26-12 12/16/96 ^ TRANSAXLE - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSAXLE COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP ^ TRANSMISSION - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSMISSION COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP FORD: 1985-86 LTD 1985-88 EXP 1985-94 TEMPO 1985-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1985-86 MARQUIS 1985-87 LN7, LYNX 1985-92 MARK VII 1985-94 TOPAZ 1985-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-96 BRONCO 1985-97 ECONOLINE, F-150-350 SERIES, RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: Torque converter replacement guidelines and torque converter/transmission (or transaxle) cooling-system cleaning procedures are now available to reduce repeat repairs. ACTION: Refer to the following guideline to properly diagnose and service torque converters and to properly clean the torque converter and transmission cooling system using forward flushing/backflushing. For diagnosis, service and cleaning, refer to to the appropriate model/year Service Manual, Sections 07-01, 07-02, 03-03, 307-01, 307-02, or 303-03. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Torque Converter - Cleaning and Replacement Guidelines > Page 5966 OASIS CODES: 501000, 502000, 503000, 504000 Diagnostic Procedure Prior to torque converter replacement, all diagnostic procedures must be followed. This is to prevent the unnecessary replacement of good torque converters. Only after a complete diagnostic evaluation can the decision be made to replace the torque converter. The normal diagnostic procedure is as follows: 1. Preliminary inspection. 2. Know and understand the customers concern. 3. Verify the concern: - Perform the Torque Converter Clutch Operation Test 4. Perform diagnostic procedures: a. Run On-Board Diagnostics - Repair all non-transmission-related Diagnostic Trouble Codes (DTCs) first. - Repair all transmission DTCs. - Rerun On-Board Diagnostic to verify repair. b. Perform Line Pressure Test c. Perform Stall Speed Test d. Diagnosis by Symptom Routines - Use the index to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed, diagnose and service as required, before servicing the torque converter. Replacement The torque converter must be replaced if one or more of the following statements are true: ^ A torque converter malfunction has been determined based on completed diagnostic procedures ^ A converter stud(s), impeller hub or bushing is damaged ^ If there is discoloration of the torque converter (due to overheating) ^ The torque converter is found to be out of specification when performing the following checks (as applicable): 1. Torque Converter One-way Clutch Check 2. End Play Check 3. Stator-to-Turbine Interference Check 4. Converter Leakage Check 5. Stator-to-Impeller Interference Check ^ If there is evidence of transmission assembly or fluid contamination due to the following failure modes: Torque converter Replacement Policy Failure Modes Major metallic failure Multiple clutches or clutch plate failures Sufficient component wear which results in metallic contamination Torque Converter & Transmission Cooling System Cleaning Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Torque Converter - Cleaning and Replacement Guidelines > Page 5967 When the torque converter is replaced, the following actions must take place: 1. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 2. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All Cooler By-Pass Valves (CBV), it equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 4. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. If the torque converter is not being replaced, the following actions must take place: 1. The torque convener must be thoroughly cleaned: a. Torque converters with drain plugs can be cleaned using the Rotunda Torque Converter Cleaner Follow the instructions included with the equipment. b. Torque converters without drain plugs can be cleaned by hand. Partially fill the converter using clean transmission fluid (as recommended for the particular transmission). Hand agitate the converter and then thoroughly drain the fluid. Refill with new fluid, specified for the transmission, and reinstall. 2. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 4. All Cooler By-Pass Valves (CBV), if equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 5. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. Required Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Page 5968 Fluid Line/Hose: Specifications TORQUE SPECIFICATIONS Fluid Cooler Line Fitting ........................................................................................................................................................ 16-24 Nm (12-17.5 ft. lbs.) Fluid Cooler Tubes (5/16 in) ...................................................................................................................................................... 16-24 Nm (12-18 ft. lbs.) Fluid Cooler Tubes (3/8 in) ........................................................................................................................................................ 24-30 Nm (18-22 ft. lbs.) Fluid Cooler Line Case Fittings ................................................................................................................................................. 20-26 Nm (15-19 ft. lbs.) Cooler Tube Nut to Case Fitting ............................................................................................................................................... 13-22 Nm (9.8-16 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Replacement Notes Fluid Line/Hose: Service and Repair Replacement Notes NOTE: MERCON Automatic Transmission Fluid is being replaced by MERCON V as a service fluid. Refer to the illustration when replacing the transmission fluid cooler tubes and hoses. NOTE: When refilling the transmission to the specified level, use Motorcraft MERCON or MERCON V Automatic Transmission Fluid or equivalent meeting FORD specification. When fluid leakage is found at the transmission fluid cooler, the transmission fluid cooler must be replaced. When one or more of the fluid cooler tubes must be replaced, each replacement fluid cooler tube must be fabricated from the same size steel tubing as the original fluid cooler tube. Use the old fluid cooler tube as a guide and bend the new fluid cooler tube as required. Add the necessary fittings and install the fluid cooler tube. After the fittings have been tightened, add fluid as needed and check for fluid leaks. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Replacement Notes > Page 5971 Fluid Line/Hose: Service and Repair Replacement REMOVAL 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Remove the front skid plate. (1) Remove the six skid plate bolts. (2) Remove the front skid plate. 3. Remove the lower air deflector. (1) Remove the three air dam bolts. (2) Remove the lower air dam. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Replacement Notes > Page 5972 4. Remove the damaged transmission fluid cooler tube. (1) Remove the three clips. (2) Disconnect the tube fittings. (3) Remove the transmission fluid cooler tube. NOTE: Note the differences in tube routing between (A) vehicles with a transmission auxiliary fluid cooler and (B) vehicles without an auxiliary fluid cooler. INSTALLATION 1. Note the differences between (A) vehicles with a transmission auxiliary fluid cooler and (B) vehicles Without an auxiliary fluid cooler. Install the transmission fluid cooler tube. (1) Position the transmission fluid cooler tube. (2) Connect the tube fittings. (3) Install the clips. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Replacement Notes > Page 5973 2. Install the transmission fluid cooler tubes. 3. Install the lower air deflector. (1) Position the lower air dam. (2) Install the three lower air dam bolts. 4. Install the front skid plate. - Install the six skid plate bolts. 5. Lower the vehicle. NOTE: If equipped With air suspension, reactivate the system by turning on the air suspension switch. 6. Fill transmission fluid to the proper level and inspect for leaks. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications Fluid Pan: Specifications TORQUE SPECIFICATIONS Transmission Fluid Pan Bolts ...................................................................................................................................................... 12-15 Nm (9-11 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - E4OD Main Regulator Booster Service Tip Fluid Pump: Technical Service Bulletins A/T - E4OD Main Regulator Booster Service Tip Article No. 97-19-20 09/15/97 TRANSMISSION - E4OD - MAIN REGULATOR BOOSTER VALVE AND SLEEVE SERVICE KIT SERVICE TIP LIGHT TRUCK: 1989-96 BRONCO 1989-97 ECONOLINE, F-150-350 SERIES, F-53 MOTORHOME CHASSIS 1997-98 EXPEDITION 1998 NAVIGATOR ISSUE: An E4OD Transmission Main Regulator Booster Valve and Sleeve Service kit has been released for service. ACTION: When servicing an E4OD transmission, inspect the main regulator booster valve and sleeve assembly for signs of wear. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify the pump is disassembled, cleaned and inspected before using this kit. 2. Refer to the appropriate Service/Workshop Manual for proper disassembly, cleaning and inspection procedures for the pump and service as required. 3. Inspect the main regulator booster valve and sleeve assembly. If the valve and sleeve show signs of wear, install kit. CAUTION: IF THE PUMP BORE THAT HOLDS THE MAIN MAIN REGULATOR BOOSTER VALVE AND SLEEVE ASSEMBLY IS DAMAGED, DO NOT USE THIS Km REPLACE THE PUMP. 4. Refer to Figure 1 for the location of the valve and sleeve. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - E4OD Main Regulator Booster Service Tip > Page 5981 5. Refer to Figure 2 for orientation of the valve and sleeve in the pump. The Main Regulator Booster Valve and Sleeve kit (E9TZ-7D003-AA) contains the following: ^ One (1) Main Regulator Booster Valve ^ One (1) Main Regulator Booster Valve Sleeve ^ One (1) Instruction Sheet (I.S. 7277) PART NUMBER PART NAME E9TZ-7DO03-AA Sleeve Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 503000, 504000, 590000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 5982 Fluid Pump: Specifications TORQUE SPECIFICATIONS Front Pump Bolts ................................................................................................................................. ...................................... 20-26 Nm (15-19 ft. lbs.) Front Pump Support Bolts .......................................................................................................................................................... 20-26 Nm (15-19 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 5983 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 5984 Fluid Pump: Service and Repair DISASSEMBLY 1. Remove the No. 1 pump support thrust washer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 5985 2. Remove the front pump support. (1) Remove the five bolts. (2) Remove the front pump support. 3. Remove the two (A) reverse clutch cylinder seals and the two (B) forward clutch cylinder seals. NOTE: The reverse clutch cylinder seals are larger than the forward clutch cylinder rings. 4. Remove the (A) inner and (B) outer pump gerotor gears. 5. Carefully pry spring retainer tabs and remove the spring retainer assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 5986 6. Remove the intermediate clutch piston. 7. Remove the (A) intermediate clutch piston inner seal and (B) intermediate clutch piston outer seal. 8. Remove and discard the front pump seal. ASSEMBLY 1. Use (A) Front Pump Seal Replacer T63L-77837-A to install the (B) front pump seal assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 5987 2. Install the (A) intermediate clutch piston inner seal and the (B) intermediate clutch piston outer seal. 3. Install the (A) intermediate clutch piston into (B) Clutch Lip Seal Protector T80L-77005-A. NOTE: Coat the intermediate clutch piston outer seal, intermediate clutch piston inner seal and pump body sealing area with petroleum jelly. 4. Install the intermediate clutch piston. (1) Position the intermediate clutch piston and Clutch Lip Seal Protector T80L-77005-A onto the pump body. (2) Push the intermediate clutch piston to the bottom of the pump body bore by exerting even pressure. 5. Locate the piston bleed hole. CAUTION: The piston bleed hole must be located at 12 o'clock position (towards the top of the transmission). NOTE: The piston bleed hole is the only round hole in the pump body. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 5988 6. Install by snapping the spring retainer assembly on pump body. 7. Install the (A) inner and (B) outer fluid pump gerotor gears. NOTE: The flats on the inner fluid pump gear have steps that must face the pump body for ease of installing the torque converter. 8. Install the (A) reverse clutch cylinder seal and the (B) forward clutch cylinder seals. NOTE: The reverse clutch cylinder seals are larger than the forward clutch cylinder seals. 9. Install new front pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 5989 10. Assemble the front pump. (1) Position the pump support to the pump body assembly. (2) Install the five bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 5990 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation The transmission control switch (TCS) is a momentary contact switch. When the switch is pressed, a signal is sent to the powertrain control module (PCM) to allow automatic shifts from first through fourth gears or first through third gears only. The PCM energizes the transmission control indicator lamp (TCIL) when the switch has been pressed to cancel overdrive. The TCIL indicates overdrive cancel mode activated (lamp on) and electronic pressure control (EPC) circuit shorted (lamp flashing) or monitored sensor failure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Page 5995 Overdrive Indicator Lamp: Testing and Inspection The TCIL indicates overdrive cancel mode activated (lamp on), electronic pressure control circuit shorted or monitored sensor failure (lamp flashing). For testing procedures, Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Shift Indicator > Component Information > Adjustments Shift Indicator: Adjustments 1. Remove the upper instrument panel steering column cover. 2. Place the transmission control selector lever in the OD position. - Rotate the transmission control selector lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise (a) position). 3. Hang an eight pound weight on the transmission control selector lever. 4. Center the pointer in the middle of the OD position. - Rotate the thumbwheel located on the bottom of the steering column to adjust the pointer. 5. Remove the eight pound weight. 6. Carefully move the shift control selector lever from detent to detent and compare with transmission settings. - Readjust if necessary. 7. Install the upper instrument panel steering column cover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Testing and Inspection Transmission Mode Indicator - A/T: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Diagrams > Page 6005 Output Shaft: Service and Repair Part 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Diagrams > Page 6006 DISASSEMBLY 1. Remove the ring gear snap ring. 2. Separate the (A) ring gear and (B) output shaft. 3. Remove the (A) output shaft hub snap ring and the (B) output shaft hub. 4. Remove the three output shaft seal rings. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Diagrams > Page 6007 5. Remove the two direct clutch seal rings. 6. Remove the (A) direct clutch hub and the (B) bearing and direct clutch inner bearing support. 7. Inspect clutch cylinder thrust surfaces, piston bore and clutch plate serrations for scores or burrs. Minor scores or burrs may be removed with crocus cloth. Replace clutch cylinder if badly scored or damaged. 8. Check fluid passage in clutch cylinder for obstructions. Clean out all fluid passages. Inspect clutch piston for scores and replace if necessary. Inspect check balls for freedom of movement and proper seating. 9. Check clutch release spring for distortion and cracks. Replace spring (including wave spring) if distorted or cracked. 10. Inspect composition clutch plates, steel clutch plates and clutch pressure plate for worn or scored bearing surfaces. Replace all parts that are deeply scored or burred. 11. Check clutch plates for flatness and fit on clutch hub serrations. Discard any plate that does not slide freely on serrations or that is not flat. 12. Check clutch hub thrust surfaces for scores and clutch hub splines for wear. 13. Remove the (A) direct clutch pack retaining ring and the (B) direct clutch pack. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Diagrams > Page 6008 14. Use (A) Clutch Spring Compressor T65L-77515-A to compress the piston return spring and remove the (B) snap ring. 15. Remove the support and spring assembly and piston. WARNING: WEAR SAFETY GLASSES WHEN USING COMPRESSED AIR. NOTE: If necessary, use regulated compressed air (207 kPa [30 psi] max pressure) to remove the clutch piston. 16. Remove the inner piston seal. 17. Remove the outer piston seal. ASSEMBLY Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Diagrams > Page 6009 1. Position (A) Direct Clutch Lip Seal Protector T80L-77234-A over the clutch cylinder hub and install the (B) inner piston seal. - Install the seal with sealing lip facing down. NOTE: Lubricate direct clutch piston inner seal and seal protector with petroleum jelly. 2. Install the clutch piston outer seal so that when the piston is installed the sealing lip points toward the bottom of the cylinder. 3. Use (A) Direct Clutch Lip Seal Protector T80L-77254-A to install the (B) direct clutch piston. NOTE: Coat inner and outer direct clutch piston seals, clutch cylinder sealing area and piston inner sealing area with petroleum jelly. 4. Install the piston return spring and retainer assembly. 5. Use (A) Clutch Spring Compressor T65L-775 1 5-A to compress the piston return spring and install the (B) retaining ring. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Diagrams > Page 6010 6. Install the (A) clutch pack and the (B) clutch pack retaining ring. - Alternate external spline (steel) plates and internal spline (friction) plates, starting with a steel plate and ending with the steel pressure plate. NOTE: Before assembly, soak new clutch discs should be soaked in transmission fluid for 15 minutes. 7. Use a (A) feeler gauge to check the clearance between the (B) clutch pack retaining ring and the (C) pressure plate. - If the clearance is not within specifications, install the correct size retaining ring and recheck clearance. 8. Install the washer and the (B) No. 7 needle bearing on the (A) direct clutch hub and install the direct clutch hub. - Install the needle bearing with the black side up, toward direct clutch hub. NOTE: Inspect the output shaft bearing surfaces for scores. Inspect the output shaft splines for wear. Inspect all bushings. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Diagrams > Page 6011 9. Install the two direct clutch seal rings. CAUTION: Make sure seals are lapped correctly. 10. Install the output shaft hub. (1) Position the output shaft hub. (2) Install the retaining ring. 11. Install the three output shaft seal rings. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Diagrams > Page 6012 12. Install the No. 8 needle bearing on the direct clutch cylinder. 13. Position the (A) direct clutch on the (B) output shaft. NOTE: Direct clutch cylinder may be installed after the output shaft ring gear is installed to the output shaft hub. 14. Install the ring gear on the output shaft. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Overdrive Planetary Gears, A/T > Component Information > Technical Service Bulletins > A/T - E4OD Unique Parts Application Overdrive Planetary Gears: Technical Service Bulletins A/T - E4OD Unique Parts Application Article No. 96-21-17 10/07/96 TRANSMISSION - E4OD - UNIQUE OVERDRIVE RING GEAR, ONE-WAY CLUTCH RETAINING RING AND SHAFT RETAINING RING - SERVICE TIP LIGHT TRUCK: 1996 BRONCO 1996-97 ECONOLINE, EXPEDITION, F SUPER DUTY, F-150-350 SERIES This TSB article is being republished in its entirety to revise the applicable models and years. ISSUE: Some 1996 and 1997 vehicles with E4OD transmissions were built with unique overdrive ring gears, one-way clutch retaining ring and center shaft retaining ring (Figure 1). ACTION: If service is required on any of these unique transmissions and replacement of either the overdrive ring gear, one-way clutch retaining ring or center shaft retaining ring is required, all three (3) parts must be replaced. Use current level parts for replacement. PART NUMBER PART NAME E9TZ-7A153-A Overdrive Ring Gear E9TZ-7G375-A Retaining Ring (2 Req'd.) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-6-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 504000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation The transmission control switch (TCS) is a momentary contact switch. When the switch is pressed, a signal is sent to the powertrain control module (PCM) to allow automatic shifts from first through fourth gears or first through third gears only. The PCM energizes the transmission control indicator lamp (TCIL) when the switch has been pressed to cancel overdrive. The TCIL indicates overdrive cancel mode activated (lamp on) and electronic pressure control (EPC) circuit shorted (lamp flashing) or monitored sensor failure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Description and Operation > Page 6021 Overdrive Indicator Lamp: Testing and Inspection The TCIL indicates overdrive cancel mode activated (lamp on), electronic pressure control circuit shorted or monitored sensor failure (lamp flashing). For testing procedures, Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > E40D Transmission Transmission Control Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > E40D Transmission > Page 6026 Transmission Control Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Page 6027 Overdrive Switch: Description and Operation The transmission control switch (TCS) is a momentary contact switch. When the switch is pressed, a signal is sent to the powertrain control module (PCM) to allow automatic shifts from first through fourth gears or first through third gears only. The PCM energizes the transmission control indicator lamp (TCIL) when the switch has been pressed to cancel overdrive. The TCIL indicates overdrive cancel mode activated (lamp on) and electronic pressure control (EPC) circuit shorted (lamp flashing) or monitored sensor failure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis Overdrive Switch: Flow of Diagnosis 1. Verify the customer concern by operating the transmission external control. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged shift lock actuator - Damaged transmission control switch - Failed fuse(s) Damaged wiring harness - Loose or corroded connections 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 6030 Overdrive Switch: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 6031 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 6032 Overdrive Switch: Pinpoint Tests Part 1 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 6033 Part 2 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 6034 Part 3 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 6035 Part 4 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 6036 Part 5 Of 5 Part 1 Of 3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 6037 Part 2 Of 3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 6038 Part 3 Of 3 Part 1 Of 4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 6039 Part 2 Of 4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 6040 Part 3 Of 4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 6041 Part 4 Of 4 Part 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 6042 Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 6043 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Testing and Inspection > Page 6044 Overdrive Switch: Service and Repair REMOVAL 1. Remove the transmission control switch (TCS). (1) Remove the TCS cover. (2) Remove the TCS. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Diagrams > Page 6048 Planetary Gears: Service and Repair PLANETARY GEAR SUPPORT AND ONE WAY CLUTCH DISASSEMBLY NOTE: Inspect the outer and inner races for scores or damaged surface areas where rollers contact the races. Inspect the rollers and springs for excessive wear or damage. Inspect the spring and cage for bent or damaged spring retainers. 1. Rotate the center support counterclockwise and lift to remove the planetary gear support. 2. Remove the planetary one-way clutch. ASSEMBLY NOTE: Inspect the outer and inner races for scores or damaged surface areas where rollers contact the races. Inspect the rollers and springs for excessive wear or damage. Inspect the spring and cage for bent or damaged spring retainers. 1. To assemble, reverse the disassembly procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair Pressure Regulating Solenoid: Service and Repair REMOVAL 1. Remove the manual control lever shaft. 2. Disconnect the electronic pressure control (EPC) solenoid electrical connector. CAUTION: Do not pull on the wires. This can damage the wires or the connector and can result in transmission solenoid or sensor failure. 3. Remove the EPC solenoid. INSTALLATION 1. Install the EPC solenoid. 2. Connect the electronic pressure control (EPC) solenoid electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Page 6052 3. Install the manual control lever shaft. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair Seals and Gaskets: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 3. Drain the transmission fluid. 4. Remove the rear driveshaft. (1) Remove the four bolts. (2) Remove the rear driveshaft. NOTE: To maintain initial driveshaft balance, mark the rear driveshaft yoke and axle flange so they may be installed in their original positions. 5. Remove the vehicle speed sensor. (1) Disconnect the electrical connector. (2) Remove the bolt. (3) Remove the VSS. 6. Use Hi-Lift Jack to support the transmission. 7. Remove the two transmission mount nuts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Page 6056 8. Remove the four transmission crossmember bolts. 9. Remove the transmission crossmember. (1) Remove the two bolts. (2) Remove the transmission crossmember. 10. Lower the transmission to access the extension housing bolts. 11. Use (A) Seal Remover and (B) Impact Slide Hammer to remove the (C) extension housing seal. 12. Remove the extension housing and gasket. (1) Remove the four bolts and two nuts. (2) Remove the extension housing and gasket. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Page 6057 INSTALLATION 1. Install the extension housing and gasket. (1) Position the extension housing gasket and the extension housing. (2) Install the four bolts and two nuts. 2. Install the new extension housing seal. (1) Align Extension Housing Seal Replacer with the seal. (2) Install the extension housing seal. 3. Raise and position the transmission. 4. Install the transmission crossmember. (1) Position the transmission crossmember. (2) Install the two bolts. 5. Install the four transmission crossmember bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Page 6058 6. Remove Hi-Lift Jack. 7. Install the two transmission mount nuts. 8. Install the VSS. (1) Install the VSS. (2) Install the bolt. (3) Connect the electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > E40D Transmission Transmission Control Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > E40D Transmission > Page 6064 Transmission Control Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Page 6065 Overdrive Switch: Description and Operation The transmission control switch (TCS) is a momentary contact switch. When the switch is pressed, a signal is sent to the powertrain control module (PCM) to allow automatic shifts from first through fourth gears or first through third gears only. The PCM energizes the transmission control indicator lamp (TCIL) when the switch has been pressed to cancel overdrive. The TCIL indicates overdrive cancel mode activated (lamp on) and electronic pressure control (EPC) circuit shorted (lamp flashing) or monitored sensor failure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis Overdrive Switch: Flow of Diagnosis 1. Verify the customer concern by operating the transmission external control. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged shift lock actuator - Damaged transmission control switch - Failed fuse(s) Damaged wiring harness - Loose or corroded connections 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 6068 Overdrive Switch: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 6069 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 6070 Overdrive Switch: Pinpoint Tests Part 1 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 6071 Part 2 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 6072 Part 3 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 6073 Part 4 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 6074 Part 5 Of 5 Part 1 Of 3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 6075 Part 2 Of 3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 6076 Part 3 Of 3 Part 1 Of 4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 6077 Part 2 Of 4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 6078 Part 3 Of 4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 6079 Part 4 Of 4 Part 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 6080 Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 6081 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Page 6082 Overdrive Switch: Service and Repair REMOVAL 1. Remove the transmission control switch (TCS). (1) Remove the TCS cover. (2) Remove the TCS. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Description and Operation Shift Interlock Switch: Description and Operation The brake shift interlock actuator prevents moving the shift lever out of the PARK position unless the brake pedal is depressed. The actuator receives a signal from the brake on/off (BOO) switch that allows movement of the shift lever. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > New Digital Transmission Range Sensor - Service Tip Transmission Position Switch/Sensor: Technical Service Bulletins New Digital Transmission Range Sensor - Service Tip Article No. 96-24-10 11/18/96 TRANSMISSION - E40D - 4R70W - 4R44E - 5R55E - NEW DIGITAL TRANSMISSION RANGE SENSOR - DIAGNOSIS SERVICE TIP LINCOLN-MERCURY: 1997 MARK VIII LIGHT TRUCK: 1997 AEROSTAR, ECONOLINE, EXPEDITION, EXPLORER, F-150, F-250, MOUNTAINEER ISSUE: Beginning with Job 1 1997, some vehicles will be equipped with a new Digital Transmission Range (DTR) sensor. The DTR sensor is located on the outside of the transmission (Figure 1) at the outer manual lever. ACTION: Refer to the following text to properly diagnose a concern with the DTR sensor. The new DTR sensor completes the start circuit in "Park" and "Neutral," the backup lamp circuit in "Reverse" and the neutral sense circuit (4X4 only) in "Neutral." The DTR sensor also opens/closes a set of four (4) switches that are monitored by the Powertrain Control Module (PCM) to determine the position of the transmission manual lever. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > New Digital Transmission Range Sensor - Service Tip > Page 6090 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > New Digital Transmission Range Sensor - Service Tip > Page 6091 To properly diagnose the DTR sensor, use the NGS, Rotunda Transmission Tester with TR/MLP Cable "E" (Figure 2) and the new DTR Sensor Overlay (Figure 4), while following the procedures outlined in the appropriate model 1997 Service Manual, Section 07-01 or appropriate model 1997 Workshop Manual, Section 307-01. The new DTR Sensor Overlay (007-00131) and updated Tester Manual was sent to all dealers in August 1996. The TR/MLP Cable "E" (007-00111) was sent to all dealers in June 1995 (refer to TSB 95-19-7). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > New Digital Transmission Range Sensor - Service Tip > Page 6092 When using Cable "E" (Figure 3) to diagnose the DTR sensor, the slide switch must be in the "Digital" position and the "Black" 12-pin connector installed on the sensor. Having the slide switch in the incorrect position or using the incorrect 12-pin connector will result in misdiagnosis and possible replacement of a good component. For diagnosis of the DTR sensor, always refer to the appropriate model 1997 Service Manual, Section 07.01 or appropriate model 1997 Workshop Manual, Section 3O7-01 for proper procedure and required equipment. OTHER APPLICABLE ARTICLES: 95-19-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 503000, 503300, 504000, 601300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 6093 Transmission Position Switch/Sensor: Specifications TORQUE SPECIFICATIONS DTR Sensor Bolts ................................................................................................................................ ..................................... 7-10 Nm (62-89 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 6094 Transmission Position Switch/Sensor: Locations Transmission View The Digital Transmission Range Sensor is located at left side of the automatic transmission. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 6095 Digital Transmission Range Sensor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 6096 Transmission Position Switch/Sensor: Adjustments NOTE: Use Digital Transmission Range (DTR) Sensor Alignment Tool to align both TR and DTR sensors. 1. Raise and support vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Disconnect the manual lever shift control cable. 3. Disconnect the TR or DTR electrical connector. 4. Remove the manual control lever. (1) Remove the nut. (2) Remove the lever. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. 5. Loosen the TR or DTR bolts. 6. Use DTR sensor alignment tool, to align the DTR or TR sensor slots. NOTE: Manual shift lever must be in the neutral position. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 6097 7. Tighten the DTR or TR sensor bolts. 8. Install the manual control lever. (1) Position the manual control lever. (2) Install a new manual lever shaft outer nut. 9. With the manual lever in overdrive connect the shift lever control cable. 10. Install the DTR sensor electrical connector. 11. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications TORQUE SPECIFICATIONS Output Shaft Speed (OSS) Sensor Bolt .......................................................................................................................................... 8-16 Nm (6-12 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 6101 Transmission Speed Sensor: Locations Transmission View The Output Shaft Speed Sensor is located at left side of transmission. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 6102 Output Shaft Speed Sensor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Specifications Shift Interlock Solenoid: Specifications TORQUE SPECIFICATIONS Shift Lock Actuator Bolts ...................................................................................................................................................... 7-11 Nm (62.5-98 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 6107 Shift Interlock Solenoid: Service and Repair REMOVAL 1. Remove the steering column. 2. Remove the insert plate and shift lock actuator. (1) Remove the three shift lock actuator bolts. (2) Remove the insert plate and shift lock actuator. 3. Remove the insert plate from the shift lock actuator. - Remove and discard the shift lock actuator clip. NOTE: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced in the field. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Switch > Component Information > Description and Operation Shift Interlock Switch: Description and Operation The brake shift interlock actuator prevents moving the shift lever out of the PARK position unless the brake pedal is depressed. The actuator receives a signal from the brake on/off (BOO) switch that allows movement of the shift lever. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams Shift Solenoid: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Specifications Shifter A/T: Specifications TORQUE SPECIFICATIONS Selector Lever Arm and Support Bolts ...................................................................................................................................... 13-17 Nm (10-12 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Specifications > Page 6117 Shifter A/T: Service and Repair REMOVAL 1. Remove the ignition lock cylinder. 2. Remove the upper steering column shroud. 3. Remove the gearshift lever. (1) Disconnect the electrical connector. (2) Remove and discard the gearshift lever pin. (3) Remove the gearshift lever. INSTALLATION 1. To install, reverse the removal procedure. NOTE: The gearshift lever pin must be replaced whenever removed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Specifications Selector Shaft: Specifications TORQUE SPECIFICATIONS Manual Lever Shaft Inner Nut .................................................................................................................................................... 26-37 Nm (19-27 ft. lbs.) Manual Lever Shaft Outer Nut ................................................................................................................................................... 30-35 Nm (22-26 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Specifications > Page 6122 Selector Shaft: Service and Repair REMOVAL NOTE: Use Digital Transmission Range (DTR) Sensor Alignment Tool to adjust TR and DTR sensors. 1. Disconnect battery ground cable. 2. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 3. Remove the front driveshaft. (1) Remove the eight front driveshaft bolts (four each end). (2) Remove the front driveshaft. NOTE: Mark the driveshaft flange and rear axle companion flange for correct alignment during installation. 4. Drain the transmission fluid and remove the fluid pan and filter. 5. Disconnect (TR) or (DTR) sensor electrical connector. 6. Disconnect the transmission shift linkage. 7. Remove the manual control lever. (1) Remove the outer manual control lever shaft nut. (2) Remove the manual control lever. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Specifications > Page 6123 CAUTION: Discard outer manual control lever shaft nut. Do not reuse. 8. Remove the transmission range TR or DTR sensor. (1) Remove the two bolts. (2) Remove the TR sensor. 9. Remove the manual control valve detent lever spring. (1) Remove the bolt. (2) Remove the manual control valve detent lever spring. 10. Remove the manual lever shaft retaining pin. NOTE: Use a shop cloth to protect the transmission case surface. 11. Remove the inner manual control lever shaft nut and slide the manual control lever shaft out of the case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Specifications > Page 6124 12. Remove the (A) manual valve detent lever and (B) parking lever actuating rod. 13. Remove the manual control lever shaft seal. CAUTION: Use care not to damage the manual control lever shaft bore. INSTALLATION 1. Use (A) Shift Lever Seal Replacer to install the (B) manual control lever seal. 2. Install the (A) manual valve detent lever and (B) parking lever actuating rod. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Specifications > Page 6125 3. Install the manual control lever shaft. (1) Install the manual control lever shaft. (2) Install the inner manual control lever shaft nut. (3) Install the manual lever shaft retaining pin. 4. Install the manual valve detent lever spring. (1) Position the manual valve detent lever spring. (2) Install the manual valve detent lever spring bolt. 5. Install the TR or DTR sensor. (1) Position the TR or DTR sensor. (2) Loosely install the two bolts. NOTE: Use the Digital Transmission Range (DTR) Sensor Alignment Tool for both DTR and TR sensors. 6. Use Digital Transmission Range (DTR) Sensor Alignment Tool to align the TR and DTR sensor slots. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Specifications > Page 6126 NOTE: Manual shift lever must be in the neutral position. 7. Tighten the DTR or TR sensor bolts and remove the Digital Transmission Range (DTR) Sensor Alignment Tool. 8. Install the manual control lever. (1) Position the manual control lever. (2) Install a new manual lever shaft outer nut. 9. With manual lever in overdrive, connect the shift control cable. 10. Install TR or DTR sensor electrical connector. 11. Install the filter and transmission fluid pan. 12. Install the front driveshaft. (1) Position the front driveshaft. (2) Install the eight front driveshaft bolts (four each end). 13. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Specifications > Page 6127 NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. 14. Connect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 15. Fill the transmission with fluid and inspect for proper operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Recalls for Shift Cable: > 97S86 > Oct > 97 > Recall A/T Shift Cable Retention Technical Service Bulletin # 97S86 Date: 971001 Recall - A/T Shift Cable Retention 97S86 SAFETY RECALL Certain 1997 and 1998 F-150/250 Series Trucks, Expeditions and Certain 1998 Navigators Automatic Transmission Shift Cable Retention. Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Recalls for Shift Cable: > 97S86 > Oct > 97 > Recall A/T Shift Cable Retention > Page 6136 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. Please Note Correct all vehicles in stock before delivery. Federal law requires dealers complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. Promptly Correct Affected vehicles on the enclosed list. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Recalls for Shift Cable: > 97S86 > Oct > 97 > Recall A/T Shift Cable Retention > Page 6137 Other eligible vehicles which are brought to your dealership. Dealer-Owner Contact Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter and schedule a service date. Regional Contact Advise regional office if: ^ an owner cannot be contacted. ^ an owner does not make a service date. Claims Submission Enter claims using DWE. See ACESII Manual, Sections 5 and 6. Warranty And Policy Manual See Sections 5 and 6 of the ACESII Manual. Refunds See Section 3-62 of the ACESII Manual. Attachment II - Labor and Parts Information Certain 1997 and 1998 F-150/250 Series Trucks and Expeditions and Certain 1998 Navigators Automatic Transmission Shift Cable Retention. Labor Allowance Parts Requirements Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels as noted below: Stock Orders Effective immediately Normal Order Process Interim Orders Effective immediately Normal Order Process Emergency Orders On or After November 24, 1997 Normal Order Process Emergency Orders Prior to November 24, 1997 Call 1-800-325-5621 Dealer Price For latest prices, check or call your: ^ Order Processing Center ^ DOES II Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Recalls for Shift Cable: > 97S86 > Oct > 97 > Recall A/T Shift Cable Retention > Page 6138 ^ Updated Price Book Excess Stock Return Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information Transmission Shift Cable Modification Affected Vehicles Certain 1997 and 1998 Model Year F-150/250 Series Trucks, Expeditions and Certain 1998 Model Year Navigators Service Procedure 1. Make sure shift cable is fully installed in steering column bracket. See Figure 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Recalls for Shift Cable: > 97S86 > Oct > 97 > Recall A/T Shift Cable Retention > Page 6139 2. Install tie strap over steering column bracket and shift cable. See Figure 2. NOTE: "Cinch" tie strap tight. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Recalls for Shift Cable: > 97S86 > Oct > 97 > Recall A/T Shift Cable Retention > Page 6140 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Recalls for Shift Cable: > 97S86 > Oct > 97 > Recall A/T Shift Cable Retention > Page 6141 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Recalls for Shift Cable: > NHTSA97V171000 > Sep > 97 > Recall 97V17100: A/T Shift Cable Defect Shift Cable: Recalls Recall 97V17100: A/T Shift Cable Defect Vehicle Description: Light duty pickup trucks and multi-purpose passenger vehicles. If the automatic transmission shift cable assembly was not fully attached to the steering column bracket, the shift cable assembly can come out of the bracket. The vehicle operator would then not be able to shift the transmission from one of the drive gear positions into the park position even though the gear shift selector would indicate "Park." The condition would not allow a disengagement of the transmission from the park position or affect proper neutral start switch operation. Unintended vehicle movement could occur if the parking brake was not set. Dealers will make the proper attachment of the transmission shift control cable to the steering column bracket and add a tie strap to that connection. Owner notification is expected to begin October 20, 1997. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. 1997 FORD TRUCK EXPEDITION 1997 FORD TRUCK F150 1997 FORD TRUCK F250 1998 FORD TRUCK EXPEDITION 1998 FORD TRUCK F150 1998 FORD TRUCK F250 1998 FORD TRUCK NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Recalls for Shift Cable: > NHTSA97V171000 > Sep > 97 > Recall 97V171000: Shift Cable Disengages Shift Cable: Recalls Recall 97V171000: Shift Cable Disengages Year: 1997, 1998 Make: LINCOLN TRUCK, FORD TRUCK Model: NAVIGATOR, EXPEDITION, F150, F250 Year of Recall: '97 Type of Report: Vehicle Potential Number of Units Affected: 866000 Summary: Vehicle Description: Light duty pickup trucks and multi-purpose passenger vehicles. If the automatic transmission shift cable assembly was not fully attached to the steering column bracket, the shift cable assembly can come out of the bracket. The vehicle operator would then not be able to shift the transmission from one of the drive gear positions into the park position even though the gear shift selector would indicate "Park." The condition would not allow a disengagement of the transmission from the park position or affect proper neutral start switch operation. Unintended vehicle movement could occur if the parking brake was not set. Dealers will make the proper attachment of the transmission shift control cable to the steering column bracket and add a tie strap to that connection. Owner notification is expected to begin October 20, 1997. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > 97S86 > Oct > 97 > Recall - A/T Shift Cable Retention Technical Service Bulletin # 97S86 Date: 971001 Recall - A/T Shift Cable Retention 97S86 SAFETY RECALL Certain 1997 and 1998 F-150/250 Series Trucks, Expeditions and Certain 1998 Navigators Automatic Transmission Shift Cable Retention. Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > 97S86 > Oct > 97 > Recall - A/T Shift Cable Retention > Page 6155 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. Please Note Correct all vehicles in stock before delivery. Federal law requires dealers complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. Promptly Correct Affected vehicles on the enclosed list. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > 97S86 > Oct > 97 > Recall - A/T Shift Cable Retention > Page 6156 Other eligible vehicles which are brought to your dealership. Dealer-Owner Contact Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter and schedule a service date. Regional Contact Advise regional office if: ^ an owner cannot be contacted. ^ an owner does not make a service date. Claims Submission Enter claims using DWE. See ACESII Manual, Sections 5 and 6. Warranty And Policy Manual See Sections 5 and 6 of the ACESII Manual. Refunds See Section 3-62 of the ACESII Manual. Attachment II - Labor and Parts Information Certain 1997 and 1998 F-150/250 Series Trucks and Expeditions and Certain 1998 Navigators Automatic Transmission Shift Cable Retention. Labor Allowance Parts Requirements Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels as noted below: Stock Orders Effective immediately Normal Order Process Interim Orders Effective immediately Normal Order Process Emergency Orders On or After November 24, 1997 Normal Order Process Emergency Orders Prior to November 24, 1997 Call 1-800-325-5621 Dealer Price For latest prices, check or call your: ^ Order Processing Center ^ DOES II Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > 97S86 > Oct > 97 > Recall - A/T Shift Cable Retention > Page 6157 ^ Updated Price Book Excess Stock Return Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information Transmission Shift Cable Modification Affected Vehicles Certain 1997 and 1998 Model Year F-150/250 Series Trucks, Expeditions and Certain 1998 Model Year Navigators Service Procedure 1. Make sure shift cable is fully installed in steering column bracket. See Figure 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > 97S86 > Oct > 97 > Recall - A/T Shift Cable Retention > Page 6158 2. Install tie strap over steering column bracket and shift cable. See Figure 2. NOTE: "Cinch" tie strap tight. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > 97S86 > Oct > 97 > Recall - A/T Shift Cable Retention > Page 6159 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > 97S86 > Oct > 97 > Recall - A/T Shift Cable Retention > Page 6160 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > NHTSA97V171000 > Sep > 97 > Recall 97V17100: A/T Shift Cable Defect Shift Cable: All Technical Service Bulletins Recall 97V17100: A/T Shift Cable Defect Vehicle Description: Light duty pickup trucks and multi-purpose passenger vehicles. If the automatic transmission shift cable assembly was not fully attached to the steering column bracket, the shift cable assembly can come out of the bracket. The vehicle operator would then not be able to shift the transmission from one of the drive gear positions into the park position even though the gear shift selector would indicate "Park." The condition would not allow a disengagement of the transmission from the park position or affect proper neutral start switch operation. Unintended vehicle movement could occur if the parking brake was not set. Dealers will make the proper attachment of the transmission shift control cable to the steering column bracket and add a tie strap to that connection. Owner notification is expected to begin October 20, 1997. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. 1997 FORD TRUCK EXPEDITION 1997 FORD TRUCK F150 1997 FORD TRUCK F250 1998 FORD TRUCK EXPEDITION 1998 FORD TRUCK F150 1998 FORD TRUCK F250 1998 FORD TRUCK NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > NHTSA97V171000 > Sep > 97 > Recall 97V171000: Shift Cable Disengages Shift Cable: All Technical Service Bulletins Recall 97V171000: Shift Cable Disengages Year: 1997, 1998 Make: LINCOLN TRUCK, FORD TRUCK Model: NAVIGATOR, EXPEDITION, F150, F250 Year of Recall: '97 Type of Report: Vehicle Potential Number of Units Affected: 866000 Summary: Vehicle Description: Light duty pickup trucks and multi-purpose passenger vehicles. If the automatic transmission shift cable assembly was not fully attached to the steering column bracket, the shift cable assembly can come out of the bracket. The vehicle operator would then not be able to shift the transmission from one of the drive gear positions into the park position even though the gear shift selector would indicate "Park." The condition would not allow a disengagement of the transmission from the park position or affect proper neutral start switch operation. Unintended vehicle movement could occur if the parking brake was not set. Dealers will make the proper attachment of the transmission shift control cable to the steering column bracket and add a tie strap to that connection. Owner notification is expected to begin October 20, 1997. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 6169 Shift Cable: Specifications TORQUE SPECIFICATIONS Shift Cable Bracket Bolts ........................................................................................................................................................ 21-29 Nm (15.5-21 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 6170 Shift Cable: Adjustments 1. Place the gearshift lever in the OD position. - Place an eight pound weight on the gearshift lever. 2. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 3. Disconnect the transmission shift cable from the manual lever. 4. Unlock the lock tab on the transmission shift cable. 5. Place the manual control lever in the OD position. (1) Place the manual control lever in the first gear position. (2) Move the manual control lever two detents to the OD position. 6. Connect the transmission shift cable to the manual control lever. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 6171 7. Lock the transmission shift cable lock tab. 8. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. 9. Remove the eight pound weight. 10. Carefully move the transmission control selector lever from detent to detent and compare with transmission settings. Verify that the vehicle will start in PARK or NEUTRAL and backup lamps illuminate in REVERSE. If not, Steps 1-5 must be repeated and include digital transmission range (DTR) or transmission range (TR) sensor adjustment in NEUTRAL. Readjust if necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 6172 Shift Cable: Service and Repair REMOVAL 1. Disconnect the transmission shift cable from the steering column. (1) Disconnect the transmission shift cable from the steering column shift tube lever. (2) Disconnect the transmission shift cable from the steering column bracket. 2. Disconnect the cable push pin. 3. Push the rubber grommet and transmission shift cable through the bulkhead. 4. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 5. Remove the transmission shift cable from the automatic transmission. (1) Disconnect the transmission shift cable from the manual control lever. (2) Depress the lock tabs to release the transmission shift cable and disconnect the transmission shift cable from the transmission shift cable bracket. 6. Remove the shift cable bracket from the transmission. (1) Remove the bolts. (2) Remove the bracket. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 6173 INSTALLATION 1. To install, reverse the removal procedure. - Adjust the shift cable. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Service and Repair Sun Gear: Service and Repair DISASSEMBLY 1. Remove the (A) reverse sun gear assembly and the (B) No. 4 forward clutch hub bearing. 2. Remove the (A) forward clutch sun gear and the (B) No. 5 forward clutch sun gear bearing. ASSEMBLY 1. The forward clutch sun gear and reverse sun gear assembly are assembled as part of the transmission assembly procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Thrust Washer/Bearing, A/T > Component Information > Technical Service Bulletins > A/T - E4OD Forward Thrust Washer Revision Thrust Washer/Bearing: Technical Service Bulletins A/T - E4OD Forward Thrust Washer Revision Article No. 96-24-18 11/18/96 TRANSMISSION - E4OD - REVISED DESIGN FORWARD PLANET THRUST WASHER SERVICE TIP LIGHT TRUCK: 1996 BRONCO 1996-97 ECONOLINE, F SUPER DUTY, F-150-350 SERIES, F-53 1997 EXPEDITION ISSUE: Some 1996 and all 1997 E4OD transmissions have been built with a needle bearing located between the forward planetary carrier and forward ring gear hub. This is a revised design for 1997 which was pulled ahead as a running change for 1996. This needle bearing replaces the # 10A thrust washer. The slots in the planet carrier for the thrust washer tabs were also removed. The forward ring gear hub was changed to accommodate the needle bearing instead of the thrust washer. ACTION: If service is required on the needle bearing, hub or planet assembly, use a new Service kit (F7TZ-7B067-AB) to service these components. This kit will service all E4OD transmissions. The new design forward planet carrier # 10A needle bearing, forward ring gear hub and forward planet assemblies are not interchangeable with the past design components. Refer to the following Service Procedure and Part Application Chart for details. SERVICE PROCEDURE NOTE: IF THE FORWARD PLANET CARRIER HAS SLOTS (FIGURE 1) FOR THE THRUST WASHER TABS, IT DOES NOT HAVE TO BE REPLACED UNLESS IT IS DAMAGED. THE PLANET CARRIER MUST HAVE SLOTS TO BE USED WITH THE # 10A THRUST WASHER. EITHER PLANET ASSEMBLY WITH OR WITHOUT SLOTS CAN BE USED WITH THE BEARING. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Thrust Washer/Bearing, A/T > Component Information > Technical Service Bulletins > A/T - E4OD Forward Thrust Washer Revision > Page 6181 Refer to Figure 1 and the Part Application Chart for correct part identification and proper part usage. Follow all normal service procedures as outlined in the appropriate model/year Service Manual, Section 07-01A or appropriate model 1997 Workshop Manual, Section 307-01. Service kit F7TZ-7B067-AB includes the following: ^ One (1) # 10A Needle Bearing ^ One (1) Forward Ring Gear Hub ^ One (1) Instruction Sheet (I.S. 7209A) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Thrust Washer/Bearing, A/T > Component Information > Technical Service Bulletins > A/T - E4OD Forward Thrust Washer Revision > Page 6182 PART NUMBER PART NAME E9TZ-7A395-A Planet Assembly F7TZ-7A398-BA Planet Assembly F7TZ-7B067-AB Service Kit F7TZ-7B067-AB Ring Gear Hub OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 504000, 590000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Customer Interest: > 02-21-1 > Oct > 02 > A/T - Torque Converter Access Plug Dislodges Torque Converter: Customer Interest A/T - Torque Converter Access Plug Dislodges Article No. 02-21-1 10/28/02 TRANSMISSION - 4R100/E4OD - TORQUE CONVERTER ACCESS EXTERNAL DUST PLUG MAY BECOME DISLODGED FORD: 1989-1996 BRONCO 1989-1997 F SUPER DUTY 1989-1998 F-250 LD, F-53 MOTORHOME 1989-2003 E SERIES, F-150 1997-2003 EXPEDITION 1999-2003 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2003 EXCURSION LINCOLN: 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD ISSUE Some vehicles equipped with the E4OD/4R100 transmission may exhibit the torque converter external access dust plug dislodging and falling out during severe duty use. This may be caused by a combination of stack up tolerance, material shrinkage over time and loading being applied to the plug during usage or cleaning of the underside of the vehicle. ACTION Obtain new plug (E9TZ-7N171-A) and apply 1/4" bead of silicone sealant around entire perimeter of part and install plug into transmission case. The silicone is to be applied in the groove of the part such that when it is installed, the sealant will till any gaps between the transmission case and the plug. SERVICE PROCEDURE 1. Obtain service part E9TZ-7N171-A, F7TZ-19554-AA and general purpose degreaser such as Motorcraft Brake Parts Cleaner, PM-4. 2. Clean transmission case casting in the area of the plug using general purpose degreaser making sure the area is free from grease and other contaminants. 3. Apply a 1/4" bead of silicone sealant F7TZ-19554-AA to plug E9TZ-7N171-A making sure that the groove in the plug is filled with silicone sealant. 4. Immediately install plug into the transmission case casting smoothing out any overflow that may occur during installation. PART NUMBER PART NAME PM-4 Motorcraft Brake Parts Cleaner E9TZ-7N171-A Plug - Converter Access F7TZ-19554-AA Ultra Silicone Sealant OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 022101A Install Torque Converter 0.2 Hr. Access External Dust Plug - 1989-1996 Bronco, 1989-1997 F-150, F250LD, F-Super Duty, E-Series, Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Customer Interest: > 02-21-1 > Oct > 02 > A/T - Torque Converter Access Plug Dislodges > Page 6191 1998-2003 F-150, Lightning, Harley Davidson, F-250LD, Super Duty F-Series, E-Series, 2000-2003 Excursion, 1989-2003 Motor Home Stripped Chassis, 1997-2003 Expedition, Navigator, 2002-2003 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 7N171 39 OASIS CODES: 504000 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 02-21-1 > Oct > 02 > A/T - Torque Converter Access Plug Dislodges Torque Converter: All Technical Service Bulletins A/T - Torque Converter Access Plug Dislodges Article No. 02-21-1 10/28/02 TRANSMISSION - 4R100/E4OD - TORQUE CONVERTER ACCESS EXTERNAL DUST PLUG MAY BECOME DISLODGED FORD: 1989-1996 BRONCO 1989-1997 F SUPER DUTY 1989-1998 F-250 LD, F-53 MOTORHOME 1989-2003 E SERIES, F-150 1997-2003 EXPEDITION 1999-2003 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2003 EXCURSION LINCOLN: 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD ISSUE Some vehicles equipped with the E4OD/4R100 transmission may exhibit the torque converter external access dust plug dislodging and falling out during severe duty use. This may be caused by a combination of stack up tolerance, material shrinkage over time and loading being applied to the plug during usage or cleaning of the underside of the vehicle. ACTION Obtain new plug (E9TZ-7N171-A) and apply 1/4" bead of silicone sealant around entire perimeter of part and install plug into transmission case. The silicone is to be applied in the groove of the part such that when it is installed, the sealant will till any gaps between the transmission case and the plug. SERVICE PROCEDURE 1. Obtain service part E9TZ-7N171-A, F7TZ-19554-AA and general purpose degreaser such as Motorcraft Brake Parts Cleaner, PM-4. 2. Clean transmission case casting in the area of the plug using general purpose degreaser making sure the area is free from grease and other contaminants. 3. Apply a 1/4" bead of silicone sealant F7TZ-19554-AA to plug E9TZ-7N171-A making sure that the groove in the plug is filled with silicone sealant. 4. Immediately install plug into the transmission case casting smoothing out any overflow that may occur during installation. PART NUMBER PART NAME PM-4 Motorcraft Brake Parts Cleaner E9TZ-7N171-A Plug - Converter Access F7TZ-19554-AA Ultra Silicone Sealant OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 022101A Install Torque Converter 0.2 Hr. Access External Dust Plug - 1989-1996 Bronco, 1989-1997 F-150, F250LD, F-Super Duty, E-Series, Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 02-21-1 > Oct > 02 > A/T - Torque Converter Access Plug Dislodges > Page 6197 1998-2003 F-150, Lightning, Harley Davidson, F-250LD, Super Duty F-Series, E-Series, 2000-2003 Excursion, 1989-2003 Motor Home Stripped Chassis, 1997-2003 Expedition, Navigator, 2002-2003 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 7N171 39 OASIS CODES: 504000 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 962612 > Dec > 96 > Torque Converter - Cleaning and Replacement Guidelines Technical Service Bulletin # 962612 Date: 961216 Torque Converter - Cleaning and Replacement Guidelines Article No. 96-26-12 12/16/96 ^ TRANSAXLE - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSAXLE COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP ^ TRANSMISSION - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSMISSION COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP FORD: 1985-86 LTD 1985-88 EXP 1985-94 TEMPO 1985-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1985-86 MARQUIS 1985-87 LN7, LYNX 1985-92 MARK VII 1985-94 TOPAZ 1985-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-96 BRONCO 1985-97 ECONOLINE, F-150-350 SERIES, RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: Torque converter replacement guidelines and torque converter/transmission (or transaxle) cooling-system cleaning procedures are now available to reduce repeat repairs. ACTION: Refer to the following guideline to properly diagnose and service torque converters and to properly clean the torque converter and transmission cooling system using forward flushing/backflushing. For diagnosis, service and cleaning, refer to to the appropriate model/year Service Manual, Sections 07-01, 07-02, 03-03, 307-01, 307-02, or 303-03. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 962612 > Dec > 96 > Torque Converter - Cleaning and Replacement Guidelines > Page 6202 OASIS CODES: 501000, 502000, 503000, 504000 Diagnostic Procedure Prior to torque converter replacement, all diagnostic procedures must be followed. This is to prevent the unnecessary replacement of good torque converters. Only after a complete diagnostic evaluation can the decision be made to replace the torque converter. The normal diagnostic procedure is as follows: 1. Preliminary inspection. 2. Know and understand the customers concern. 3. Verify the concern: - Perform the Torque Converter Clutch Operation Test 4. Perform diagnostic procedures: a. Run On-Board Diagnostics - Repair all non-transmission-related Diagnostic Trouble Codes (DTCs) first. - Repair all transmission DTCs. - Rerun On-Board Diagnostic to verify repair. b. Perform Line Pressure Test c. Perform Stall Speed Test d. Diagnosis by Symptom Routines - Use the index to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed, diagnose and service as required, before servicing the torque converter. Replacement The torque converter must be replaced if one or more of the following statements are true: ^ A torque converter malfunction has been determined based on completed diagnostic procedures ^ A converter stud(s), impeller hub or bushing is damaged ^ If there is discoloration of the torque converter (due to overheating) ^ The torque converter is found to be out of specification when performing the following checks (as applicable): 1. Torque Converter One-way Clutch Check 2. End Play Check 3. Stator-to-Turbine Interference Check 4. Converter Leakage Check 5. Stator-to-Impeller Interference Check ^ If there is evidence of transmission assembly or fluid contamination due to the following failure modes: Torque converter Replacement Policy Failure Modes Major metallic failure Multiple clutches or clutch plate failures Sufficient component wear which results in metallic contamination Torque Converter & Transmission Cooling System Cleaning Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 962612 > Dec > 96 > Torque Converter - Cleaning and Replacement Guidelines > Page 6203 When the torque converter is replaced, the following actions must take place: 1. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 2. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All Cooler By-Pass Valves (CBV), it equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 4. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. If the torque converter is not being replaced, the following actions must take place: 1. The torque convener must be thoroughly cleaned: a. Torque converters with drain plugs can be cleaned using the Rotunda Torque Converter Cleaner Follow the instructions included with the equipment. b. Torque converters without drain plugs can be cleaned by hand. Partially fill the converter using clean transmission fluid (as recommended for the particular transmission). Hand agitate the converter and then thoroughly drain the fluid. Refill with new fluid, specified for the transmission, and reinstall. 2. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 4. All Cooler By-Pass Valves (CBV), if equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 5. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. Required Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 96249 > Nov > 96 > A/T Torque Converter - Leak Test Procedure Torque Converter: All Technical Service Bulletins A/T Torque Converter - Leak Test Procedure Article No. 96-24-9 11/18/96 TORQUE CONVERTER - LEAK TEST PROCEDURE - SERVICE TIP FORD: 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1984-92 MARK VII 1984-94 TOPAZ 1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1984-90 BRONCO II 1984-96 BRONCO 1984-97 ECONOLINE, F-150-350 SERIES, RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: A new torque converter leak test tool has been released. The current leak test tool has been discontinued by the manufacturer. The new tool will be available to all dealers in 1997. ACTION: When using the new leak test tool, a new procedure must be followed. Refer to the following Service Procedure and/or the 1997 Service/Workshop Manuals when using the new leak test tool. NEW TOOL NUMBER Description Tool Number Torque converter Leak Test Tool and Gasket 014-R1075 SERVICE PROCEDURE 1. Clean the outside surface of the torque converter. CAUTION: BE CAREFUL NOT TO DAMAGE THE CONVERTER HUB FINISH WHEN INSTALLING THE TOOL. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 96249 > Nov > 96 > A/T Torque Converter - Leak Test Procedure > Page 6208 2. Install the Torque Converter Leak Test Tool and Gasket (O14-R1075) into the converter hub. Figure 1. WARNING: ALWAYS USE PROPER SAFETY PROCEDURES WHILE USING PRESS. CAUTION: DO NOT DAMAGE THE CONVERTER BY APPLYING EXCESSIVE FORCE FROM THE PRESS. USE ONLY ENOUGH FORCE TO SEAL TOOL INTO THE CONVERTER. 3. Place the torque converter with the tool installed into press and apply enough force to seal tool into the converter. Figure 2. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 96249 > Nov > 96 > A/T Torque Converter - Leak Test Procedure > Page 6209 4. Using clean, dry shop air only, apply air pressure of 552 kPa (80 psi) maximum to the valve on the tool. Refer to Figure 3. 5. With air pressure applied to the valve, inspect for any air leaks at the studs, seams and pilot hub. A soap bubble solution may be applied around those areas to aid in diagnosis. If any leaks are present, replace the converter. 6. Disconnect the air line and release the air pressure from the tool by pulling on the release ring and then slowly releasing the press. Refer to Figure 4. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 96249 > Nov > 96 > A/T Torque Converter - Leak Test Procedure > Page 6210 7. Turn the torque converter and tool upside down and reinstall into the press. Repeat Steps 2-6 to check for leaks on the opposite side. Refer to Figure 5. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 504000, 510000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Torque Converter: > 962612 > Dec > 96 > Torque Converter - Cleaning and Replacement Guidelines Technical Service Bulletin # 962612 Date: 961216 Torque Converter - Cleaning and Replacement Guidelines Article No. 96-26-12 12/16/96 ^ TRANSAXLE - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSAXLE COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP ^ TRANSMISSION - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSMISSION COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP FORD: 1985-86 LTD 1985-88 EXP 1985-94 TEMPO 1985-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1985-86 MARQUIS 1985-87 LN7, LYNX 1985-92 MARK VII 1985-94 TOPAZ 1985-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-96 BRONCO 1985-97 ECONOLINE, F-150-350 SERIES, RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: Torque converter replacement guidelines and torque converter/transmission (or transaxle) cooling-system cleaning procedures are now available to reduce repeat repairs. ACTION: Refer to the following guideline to properly diagnose and service torque converters and to properly clean the torque converter and transmission cooling system using forward flushing/backflushing. For diagnosis, service and cleaning, refer to to the appropriate model/year Service Manual, Sections 07-01, 07-02, 03-03, 307-01, 307-02, or 303-03. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Torque Converter: > 962612 > Dec > 96 > Torque Converter - Cleaning and Replacement Guidelines > Page 6216 OASIS CODES: 501000, 502000, 503000, 504000 Diagnostic Procedure Prior to torque converter replacement, all diagnostic procedures must be followed. This is to prevent the unnecessary replacement of good torque converters. Only after a complete diagnostic evaluation can the decision be made to replace the torque converter. The normal diagnostic procedure is as follows: 1. Preliminary inspection. 2. Know and understand the customers concern. 3. Verify the concern: - Perform the Torque Converter Clutch Operation Test 4. Perform diagnostic procedures: a. Run On-Board Diagnostics - Repair all non-transmission-related Diagnostic Trouble Codes (DTCs) first. - Repair all transmission DTCs. - Rerun On-Board Diagnostic to verify repair. b. Perform Line Pressure Test c. Perform Stall Speed Test d. Diagnosis by Symptom Routines - Use the index to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed, diagnose and service as required, before servicing the torque converter. Replacement The torque converter must be replaced if one or more of the following statements are true: ^ A torque converter malfunction has been determined based on completed diagnostic procedures ^ A converter stud(s), impeller hub or bushing is damaged ^ If there is discoloration of the torque converter (due to overheating) ^ The torque converter is found to be out of specification when performing the following checks (as applicable): 1. Torque Converter One-way Clutch Check 2. End Play Check 3. Stator-to-Turbine Interference Check 4. Converter Leakage Check 5. Stator-to-Impeller Interference Check ^ If there is evidence of transmission assembly or fluid contamination due to the following failure modes: Torque converter Replacement Policy Failure Modes Major metallic failure Multiple clutches or clutch plate failures Sufficient component wear which results in metallic contamination Torque Converter & Transmission Cooling System Cleaning Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Torque Converter: > 962612 > Dec > 96 > Torque Converter - Cleaning and Replacement Guidelines > Page 6217 When the torque converter is replaced, the following actions must take place: 1. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 2. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All Cooler By-Pass Valves (CBV), it equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 4. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. If the torque converter is not being replaced, the following actions must take place: 1. The torque convener must be thoroughly cleaned: a. Torque converters with drain plugs can be cleaned using the Rotunda Torque Converter Cleaner Follow the instructions included with the equipment. b. Torque converters without drain plugs can be cleaned by hand. Partially fill the converter using clean transmission fluid (as recommended for the particular transmission). Hand agitate the converter and then thoroughly drain the fluid. Refill with new fluid, specified for the transmission, and reinstall. 2. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 4. All Cooler By-Pass Valves (CBV), if equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 5. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. Required Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Torque Converter: > 96249 > Nov > 96 > A/T Torque Converter - Leak Test Procedure Torque Converter: All Technical Service Bulletins A/T Torque Converter - Leak Test Procedure Article No. 96-24-9 11/18/96 TORQUE CONVERTER - LEAK TEST PROCEDURE - SERVICE TIP FORD: 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1984-92 MARK VII 1984-94 TOPAZ 1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1984-90 BRONCO II 1984-96 BRONCO 1984-97 ECONOLINE, F-150-350 SERIES, RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: A new torque converter leak test tool has been released. The current leak test tool has been discontinued by the manufacturer. The new tool will be available to all dealers in 1997. ACTION: When using the new leak test tool, a new procedure must be followed. Refer to the following Service Procedure and/or the 1997 Service/Workshop Manuals when using the new leak test tool. NEW TOOL NUMBER Description Tool Number Torque converter Leak Test Tool and Gasket 014-R1075 SERVICE PROCEDURE 1. Clean the outside surface of the torque converter. CAUTION: BE CAREFUL NOT TO DAMAGE THE CONVERTER HUB FINISH WHEN INSTALLING THE TOOL. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Torque Converter: > 96249 > Nov > 96 > A/T Torque Converter - Leak Test Procedure > Page 6222 2. Install the Torque Converter Leak Test Tool and Gasket (O14-R1075) into the converter hub. Figure 1. WARNING: ALWAYS USE PROPER SAFETY PROCEDURES WHILE USING PRESS. CAUTION: DO NOT DAMAGE THE CONVERTER BY APPLYING EXCESSIVE FORCE FROM THE PRESS. USE ONLY ENOUGH FORCE TO SEAL TOOL INTO THE CONVERTER. 3. Place the torque converter with the tool installed into press and apply enough force to seal tool into the converter. Figure 2. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Torque Converter: > 96249 > Nov > 96 > A/T Torque Converter - Leak Test Procedure > Page 6223 4. Using clean, dry shop air only, apply air pressure of 552 kPa (80 psi) maximum to the valve on the tool. Refer to Figure 3. 5. With air pressure applied to the valve, inspect for any air leaks at the studs, seams and pilot hub. A soap bubble solution may be applied around those areas to aid in diagnosis. If any leaks are present, replace the converter. 6. Disconnect the air line and release the air pressure from the tool by pulling on the release ring and then slowly releasing the press. Refer to Figure 4. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Torque Converter: > 96249 > Nov > 96 > A/T Torque Converter - Leak Test Procedure > Page 6224 7. Turn the torque converter and tool upside down and reinstall into the press. Repeat Steps 2-6 to check for leaks on the opposite side. Refer to Figure 5. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 504000, 510000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Page 6225 Torque Converter: Specifications OPERATIONAL SPECIFICATIONS End Play New or Rebuilt ...................................................................................................................................................... 0.355-1.04 mm (0.014-0.041 inch) Used ............................................................................................. ......................................................................... 0.355-1.87 mm (0.014-0.074 inch) TORQUE SPECIFICATIONS Torque Converter Drain Plug ..................................................................................................................................................... 28-30 Nm (21-23 ft. lbs.) Torque Converter Nuts ................................................................................ ............................................................................... 27-46 Nm (20-34 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Page 6226 Torque Converter: Description and Operation DESCRIPTION Torque Converter The transmission uses a four-element torque converter to transmit and multiply torque. It contains the standard three elements which transmit and multiply torque: Impeller. - Turbine. - Reactor. - Torque converter clutch. The torque converter clutch increases fuel economy in 3rd and 4th gears. OPERATION The operation of the torque converter components is as follows: Rotation of the converter housing and impeller set the fluid in motion. - The turbine reacts to the fluid motion from the impeller, transferring rotation to the geartrain. The reactor redirects fluid going back into the impeller, allowing for torque multiplication. The addition of a torque converter clutch to the torque converter provides a mechanical link between the converter housing and the engine, allowing for direct transfer of power from the engine to the geartrain. The torque converter clutch is applied and released by fluid pressure, which is controlled by the powertrain control module (PCM) through a torque converter clutch solenoid (TCC solenoid) in the main control valve body. IMPELLER AND COVER The impeller and cover drive the impeller blades, contain hydraulic fluid, and provide a mating surface for the torque converter clutch. The impeller hub also drives the fluid pump gear. TURBINE The turbine is a sectioned, donut-shaped steel stamping that is splined to the input shaft. It is driven by fluid from the impeller and transmits this power to the geartrain. Because of its basic shape, the turbine automatically directs fluid back to the impeller. REACTOR The reactor redirects the fluid flow returned to the impeller from the turbine so that the fluid moves in the same direction as engine/impeller rotation. This action aids in torque multiplication because it adds torque to that already supplied by the engine. The reactor contains a one-way clutch that holds it stationary when torque multiplication is necessary, but allows freewheeling at higher speeds when torque multiplication is not necessary. TORQUE CONVERTER CLUTCH The pressure plate attaches to the back of the turbine and can be applied against the cover to allow for a mechanical transfer of engine torque to the geartrain. This occurs mainly in third and fourth gears when torque multiplication is no longer necessary. (Converter clutch application may also occur in second gear under certain conditions.) The pressure plate works much like a regular mechanical clutch. Apply, release and controlled slip of the clutch are controlled by opposing fluid forces on each side of the pressure plate. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Flow of Diagnosis Torque Converter: Flow of Diagnosis Prior to torque converter replacement, all diagnostic procedures must be followed. This is to prevent the unnecessary replacement of good torque converters. Only after a complete diagnostic evaluation can the decision be made to replace the torque converter. Begin with the normal diagnostic procedures as follows: 1. Preliminary Inspection. 2. Know and Understand the Customer's Concern. 3. Verify the Concern-Perform the Torque Converter Clutch Operation Test. 4. Perform Diagnostic Procedures. (1) Run on-board diagnostics. - Repair all non-transmission related DTCs first. - Repair all transmission DTCs. - Rerun on-board diagnostics to verify repair. (2) Perform Line Pressure Test. (3) Perform Stall Speed Test. (4) Perform Diagnosis by Symptom routines. - Use the index to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed; diagnose and service as required before servicing the torque converter. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Flow of Diagnosis > Page 6229 Torque Converter: Component Tests and General Diagnostics End Play Check 1. Insert End Play Checking Tool T80L-7902-A into the torque converter pump drive. (1) Position End Play Checking Tool T80L-7902-A. (2) Tighten the inner post until the tool is securely locked. 2. Attach Dial Indicator With Bracketry TOOL-4201-C to End Play Checking Tool T80L-7902-A. - Position the dial indicator bottom on the converter pump drive hub and zero the dial. 3. Lift up on End Play Checking Tool T80L-7902-A and note the dial indicator reading. - If the reading exceeds end play limits, replace the torque converter. Torque Converter End Play New or Rebuilt: 0.355-1.04 mm (0.014-0.041 inch) Max. Used: 0.355-1.87 mm (0.014-0.074 inch) Max. 4. Remove the dial indicator and tool. Leakage Checks 1. Clean the outside surface of the torque converter. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Flow of Diagnosis > Page 6230 2. Install Torque Converter Leak Check Tool and Gasket 01 4-R1075 into convert hub. 3. Position torque converter with installed leak check tool into the press. 4. Secure the press. Apply enough force from the press to seal tool into the torque converter. WARNING: ALWAYS FOLLOW PROPER SAFETY PROCEDURES WHILE USING PRESS. 5. Apply air pressure to valve on leak check tool. NOTE: Use clean dry shop air. 6. With air pressure applied to valve, inspect for leaks at studs, seams and pilot hub. A soap bubble solution may be applied around those areas to aid in diagnosis. If leaks are present, replace the converter. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Flow of Diagnosis > Page 6231 7. Remove air hose. Release pressure and then slowly release press. 8. Rotate torque converter and tool, then reinstall into press with tool up. 9. Secure press. Apply enough force from press to seal tool into torque converter. WARNING: ALWAYS FOLLOW PROPER SAFETY PROCEDURES WHILE USING PRESS. 10. Apply air pressure to valve on leak check tool. NOTE: Use clean dry shop air. 11. With air pressure applied to valve, inspect for leaks at converter hub, seams and studs. A soap bubble solution may be applied around those areas Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Flow of Diagnosis > Page 6232 to aid in diagnosis. If leaks are present, replace converter. 12. Remove air hose. Release pressure and then slowly release press. Remove converter. Remove tool. Stator to Impeller Interference Check 1. Position the front pump support with the splines up. NOTE: Front pump support may remain in front pump support and gear during this test. 2. Mount (A) torque converter on the (B) front pump support with the splines on the one-way clutch inner race, engaging the mating splines of the front pump support. 3. Hold the (A) front pump support stationary and rotate the (B) torque converter counterclockwise. - The torque converter should rotate freely with no signs of scraping. - If there are signs of scraping, replace the torque converter. Stator to Turbine Interference Check 1. Position the torque converter with the pump drive up. NOTE: Front pump support may remain in front pump support and gear during this test. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Flow of Diagnosis > Page 6233 2. Install the (A) front pump support to engage the mating splines of the front pump support shaft on the (B) torque converter. 3. Install the forward clutch cylinder and shaft engaging the splines with the rear clutch hub. 4. Check for stator to turbine interference. (1) Hold the front pump support stationary. (2) Attempt to rotate the forward clutch cylinder and shaft. - The turbine and torque converter clutch assemblies should rotate in both directions not exceeding maximum torque of 9.5 Nm (7 lb/ft) without any signs of metallic interference or scraping noise. 5. If interference exists, the stator front thrust washer may be worn, allowing the stator to hit the turbine. In such cases, the torque converter must be replaced. The converter crankshaft pilot should be checked for nicks or damaged surfaces that could cause interference when installing the torque converter into the crankshaft. Check the converter front impeller hub for nicks or sharp edges that would damage the pump seal. Torque Converter Operation Test This test verifies that the torque converter clutch control system and the torque converter are operating properly. 1. Perform Quick Test. Check for DTCs P0741, P1741, P0743, P1742, P1743, P1744, P1767 and P1740. Refer to Pinpoint Test C for diagnosis. 2. Connect a tachometer to the engine. 3. Bring the engine to normal operating temperature by driving the vehicle at highway speeds for approximately 15 minutes in OD position. 4. After normal operating temperature is reached, maintain a constant vehicle speed of about 80 km/h (50 mph) and tap brake pedal with the left foot. 5. Engine rpm should increase when brake pedal is tapped, and decrease about five seconds after pedal is released. If this does not occur, refer to Torque Converter Clutch Operation Concerns in the Diagnosis by Symptom Chart. 6. If the vehicle stalls in OD or manual 2 at idle with vehicle at a stop, move the transmission range selector lever to manual 1 position. If the vehicle stalls, refer to Torque Converter Clutch Operation Concerns under Torque Converter diagnosis by symptom. Repair as required. If the vehicle does not stall in OD, refer to electrical diagnosis for the PCM and the vehicle harness diagnosis in Pinpoint Test C. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Page 6234 Torque Converter: Service and Repair NOTE:When the transmission has been repaired for internal damage the torque converter must be cleaned using a mechanically agitated cleaner. 1. Use Torque Converter/Oil Cooler Cleaner to clean and flush the torque converter. 2. After flushing, drain the remainder of the solvent through the converter access plug. 3. Add 1.9 liter (2 qt.) of clean transmission fluid to the converter and agitate by hand. 4. Thoroughly drain the solution through the converter access plug. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Specifications Torque Converter Clutch: Specifications TORQUE SPECIFICATIONS TCC Solenoid Bolt ............................................................................................................................................................. 11-15 Nm (100-130 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Testing and Inspection > One Way Clutch Check Torque Converter Clutch: Testing and Inspection One Way Clutch Check 1. Insert Converter Clutch Holding Tool T77L-7902-R in one of the grooves in the stator thrust washer. 2. Install Converter Clutch Torquing Tool T76L-7902-C in the converter pump drive. 3. Use a (A) torque wrench to turn (B) Converter Clutch Torquing Tool T76L-7902-C counterclockwise hold (C) Converter Clutch Torquing Tool T76L-7902-C. The converter should lock up and hold torque. - The torque converter one-way clutch should rotate freely in the clockwise direction. - Try the clutch for lockup and hold in at least five positions. - If the torque converter fails the lockup test torque, replace the torque converter. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Testing and Inspection > One Way Clutch Check > Page 6240 Torque Converter Clutch: Testing and Inspection Torque Converter Operation Test This test verifies that the torque converter clutch control system and the torque converter are operating properly. 1. Perform Quick Test. Check for DTCs P0741, P1741, P0743, P1742, P1743, P1744, P1767 and P1740. Refer to Pinpoint Test C for diagnosis. 2. Connect a tachometer to the engine. 3. Bring the engine to normal operating temperature by driving the vehicle at highway speeds for approximately 15 minutes in OD position. 4. After normal operating temperature is reached, maintain a constant vehicle speed of about 80 km/h (50 mph) and tap brake pedal with the left foot. 5. Engine rpm should increase when brake pedal is tapped, and decrease about five seconds after pedal is released. If this does not occur, refer to Torque Converter Clutch Operation Concerns in the Diagnosis by Symptom Chart. 6. If the vehicle stalls in OD or manual 2 at idle with vehicle at a stop, move the transmission range selector lever to manual 1 position. If the vehicle stalls, refer to Torque Converter Clutch Operation Concerns under Torque Converter diagnosis by symptom. Repair as required. If the vehicle does not stall in OD, refer to electrical diagnosis for the PCM and the vehicle harness diagnosis in Pinpoint Test C. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator Transmission Cooler: Customer Interest A/T Cooler - Fluid Leaks at Radiator Article No. 00-9-1 DATE 5/1/00 TITLE LEAK - TRANSMISSION FLUID LEAKS AT RADIATOR - VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSION AND TRANSMISSION OIL COOLER IN RADIATOR END TANK FORD: 1997-2000 MUSTANG, EXPEDITION, EXPLORER, F-150, F-250 LD 1998-2000 RANGER 1999-2000 SUPER DUTY F SERIES LINCOLN: 1998-2000 NAVIGATOR MERCURY: 1998-2000 MOUNTAINEER This TSB is being republished in its entirety to update the vehicles affected and to update the Service Procedure. ISSUE Transmission fluid may leak between the radiator transmission oil cooler and the transmission oil cooler fitting (NOT the cooler line into the fitting), which may result in a residue of transmission fluid on the radiator tank around the transmission oil cooler fitting. This may be caused by insufficient thread sealer on the transmission oil cooler fitting. NOTE: THIS TSB DOES NOT APPLY TO TRANSMISSION FLUID LEAKAGE AT THE TRANSMISSION LINE TO TRANSMISSION OIL COOLER FITTING. ACTION Install O-ring W705181-S onto the transmission oil cooler fitting. The O-ring is designed to seal the leak and reduce the possibility of transmission fluid leakage. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify that transmission fluid is leaking between the transmission oil cooler and the transmission oil cooler fitting (NOT the transmission cooler line fitting into the transmission oil cooler fitting). Refer to Figure 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 6249 2. Remove the radiator from the vehicle following Workshop Manual procedure. Place the radiator on a flat surface so that the transmission oil cooler fittings are facing upward. Refer to Figure 2. 3. Clean the area around the transmission oil cooler fitting. This will insure that contaminants do not enter the transmission oil cooler when the transmission oil cooler fittings are removed. CAUTION: OIL-BASED SOLVENTS AND CLEANERS SHOULD NOT BE USED WHEN CLEANING THE RADIATOR. OIL-BASED SOLVENTS AND CLEANERS CAN DAMAGE THE RADIATOR END TANK SEALS AND CAUSE LEAKS. 4. Remove the upper transmission oil cooler fitting. NOTE: REMOVE ONLY ONE (1) TRANSMISSION OIL COOLER FITTING AT A TIME, OTHERWISE THE COOLER MAY DROP INTO THE RADIATOR. 5. Once the fitting is removed from the transmission oil cooler, verify that there is a gasket between the transmission oil cooler and the inside of the radiator tank. If there is no gasket, replace the radiator. If the gasket is in place, continue to Step 6. 6. Inspect the transmission oil cooler fitting threads for damage. If the threads are damaged, replace the radiator. If the threads show no sign of damage, continue to Step 7. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 6250 7. Install O-ring W705181-S on the transmission oil cooler fitting. Refer to Figures 2 and 3. CAUTION: THREAD SEALANT OR TAPE SHOULD NEVER BE USED ON THE THREADS OF THE TRANSMISSION OIL COOLER FITTING. THE USE OF SUCH MATERIALS WILL CREATE A LEAK PATH. 8. Making sure that the gasket between the transmission oil cooler and the inside of the radiator tank is still in place, reinstall the transmission oil cooler fitting. The fitting should be torqued to 38-45 N.m (28-33 lb-ft). NOTE:: DO NOT USE AIR TOOLS TO TORQUE THE TRANSMISSION OIL COOLER FITTING. USE A HAND-OPERATED TORQUE WRENCH ONLY. 9. Repeat Steps 2-8 for the other transmission oil cooler fitting. This fitting should also have the O-ring replaced even if it is not leaking. 10. Make sure that no radiator coolant has entered the transmission oil cooler. Reinstall the radiator in the vehicle following Workshop Manual procedure. 11. Verify that both the transmission and the engine cooling system have the proper fluid levels outlined in the Workshop Manual. PARTS INFORMATION LABOR OPERATION APPLICATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 6251 OTHER APPLICABLE ARTICLES: NONE SUPERCEDES: 99-4-6 WARRANTY STATUS OPERATION DESCRIPTION DEALER CODING OASIS CODES: 402000, 510000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 03-14-8 > Jul > 03 > A/T - Cooler Flushing Service Tips Transmission Cooler: All Technical Service Bulletins A/T - Cooler Flushing Service Tips Article No. 03-14-8 07/21/03 TRANSMISSION - NEW TRANSMISSION COOLER FLUSHER - SERVICE TIPS FORD: 1992-1997 CROWN VICTORIA, PROBE, THUNDERBIRD 1992-2003 ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1992-1996 BRONCO 1992-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1992-1999 F-250 LD 1992-2003 ECONOLINE, EXPLORER, F-150, RANGER 1995-2003 WINDSTAR 1997-2003 EXPEDITION 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1992-1997 TOWN CAR 1992-2002 CONTINENTAL 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD 2003 AVIATOR MERCURY: 1992-1997 COUGAR, GRAND MARQUIS 1992-2000 TRACER 1992-2003 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER This article supersedes TSB 00-1-5. ISSUE The number one cause for repeat transmission repairs is that contamination from the transmission cooler system (lines and tank) will work their way back into the rebuilt or new transmission. For this reason a new transmission cooler flusher has been released, "Turbo-Tank Heated Cooler Line Flusher" Rotunda Tool number 22-00001. ACTION The transmission cooling system (cooler and lines) MUST be flushed every time the transmission is overhauled or replaced in order to minimize the likelihood of repeat repairs. The use of this new "Turbo-Tank Heated Cooler Line Flusher" (222-00001) is the most effective way to remove contamination from its cooling system. Refer to the following Service Procedure and Equipment instructions (supplied with the "Turbo-Tank Heated Cooler Line Flusher"). SERVICE PROCEDURE Prior methods of cooler flushing have not obtained the level of cooler cleaning and contaminant removal that is required to prevent repeat repairs. The "Turbo-Tank Heated Cooler Line Flusher" uses heated Automatic Transmission Fluid (ATF) and a pulsating action to loosen system contamination. Previous equipment used solvents to clean & flush coolers, lines and torque-converters. There are 2 issues with this method: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 03-14-8 > Jul > 03 > A/T - Cooler Flushing Service Tips > Page 6257 ^ Residual solvent contamination can cause damage to friction bonding materials within the transmission (Clutches and Bands). ^ Lack of fluid heating and agitation prevents this method from completely removing contamination from lines, in-radiator coolers and auxiliary coolers. Aerosol Solvents should never be used for several reasons. ^ They do not provide the volume necessary to remove heavy contaminants. ^ They evaporate quickly and essentially leave contaminants in pockets, bends, or wherever they are as the solvent dries. NOTE YOU MUST IDENTIFY THE RETURN COOLER LINE TO START THE BACK FLUSHING PROCEDURE. A quick way to identify the return cooler line (fluid coming out of the cooler and returning to the transmission) is to locate the return cooler line fitting on the transmission case. Refer to the following lists: Rear Wheel Drive ^ TORQSHIFT, 4R100, E40D, C6 - The REAR transmission case filling receives the return line. ^ 4R70W, AODE, AOD - The TOP transmission case filling receives the return line. ^ A4LD, 4R44/55E, 5R55E, 5R55N, 5R55W, 5R55S - The TOP transmission case filling receives the return line. Front Wheel Drive ^ CD4E - The REAR or Pump End transaxle case fitting receives the return line. ^ 4F27E - The REAR or Cover End transaxle case fitting receives the return line. ^ AXOD, AXODE, AX4S, AX4N, 4F50N - The BOTTOM transaxle cooler line fitting receives the return line. NOTE IF AN IN-LINE FILTER HAS BEEN INSTALLED IN THE COOLER LINE, IT MUST BE REMOVED BEFORE FLUSHING THE COOLER OR COOLER LINES. Purge the cooler and cooler line before flushing: Located on the "Turbo-Tank Heated Cooler Line Flusher" is a fluid transfer and purge valve. This valve can be used to purge the cooler and cooler lines of contaminated fluid before starting the back flush procedure of the fluid cooling system (refer to step 5a of this Service Procedure or Equipment instructions, supplied with the "Turbo-Tank Heated Cooler Line Flusher"). Flush Procedure 1. Check and top off fluid level of the "Turbo-Tank Heated Cooler Line Flusher" tank with transmission fluid. 2. Allow the fluid in the flusher 15-30 minutes to heat up to 140° F (60° C) before using. 3. Install line adapters into the transmission cooler lines. 4. Attach the flusher's blue line to the transmission return cooler line quick disconnect. 5. Attach the flusher's red line to the transmission outlet cooler line quick disconnect. a. Follow equipment instructions, to purge cooler lines and cooler prior to starting flushing procedure (using factory installed purge valve and clear hose on "Turbo-Tank Heated Cooler Line Flusher"). 6. Allow the cooling system to back-flush for 10-15 minutes, then flush the cooler in a forward/normal flow direction for an additional 10-15 minutes. For ordering information on this new "Turbo-Tank Heated Cooler Line Flusher" (222-00001), contact Rotunda at 800-ROTUNDA (800-768-8632 or outside U.S. 262-656-5805). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 03-14-8 > Jul > 03 > A/T - Cooler Flushing Service Tips > Page 6258 CAUTION THIS FLUSHER CANNOT BE USED TO FLUSH COOLERS ON VEHICLES EQUIPPED WITH THE TEMPERATURE BYPASS-TYPE TRANSMISSION COOLER CURRENTLY FOUND IN 1998-2003 CROWN VICTORIA, GRAND MARQUIS, AND TOWN CAR VEHICLES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-1-5 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator Transmission Cooler: All Technical Service Bulletins A/T Cooler - Fluid Leaks at Radiator Article No. 00-9-1 DATE 5/1/00 TITLE LEAK - TRANSMISSION FLUID LEAKS AT RADIATOR - VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSION AND TRANSMISSION OIL COOLER IN RADIATOR END TANK FORD: 1997-2000 MUSTANG, EXPEDITION, EXPLORER, F-150, F-250 LD 1998-2000 RANGER 1999-2000 SUPER DUTY F SERIES LINCOLN: 1998-2000 NAVIGATOR MERCURY: 1998-2000 MOUNTAINEER This TSB is being republished in its entirety to update the vehicles affected and to update the Service Procedure. ISSUE Transmission fluid may leak between the radiator transmission oil cooler and the transmission oil cooler fitting (NOT the cooler line into the fitting), which may result in a residue of transmission fluid on the radiator tank around the transmission oil cooler fitting. This may be caused by insufficient thread sealer on the transmission oil cooler fitting. NOTE: THIS TSB DOES NOT APPLY TO TRANSMISSION FLUID LEAKAGE AT THE TRANSMISSION LINE TO TRANSMISSION OIL COOLER FITTING. ACTION Install O-ring W705181-S onto the transmission oil cooler fitting. The O-ring is designed to seal the leak and reduce the possibility of transmission fluid leakage. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify that transmission fluid is leaking between the transmission oil cooler and the transmission oil cooler fitting (NOT the transmission cooler line fitting into the transmission oil cooler fitting). Refer to Figure 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 6263 2. Remove the radiator from the vehicle following Workshop Manual procedure. Place the radiator on a flat surface so that the transmission oil cooler fittings are facing upward. Refer to Figure 2. 3. Clean the area around the transmission oil cooler fitting. This will insure that contaminants do not enter the transmission oil cooler when the transmission oil cooler fittings are removed. CAUTION: OIL-BASED SOLVENTS AND CLEANERS SHOULD NOT BE USED WHEN CLEANING THE RADIATOR. OIL-BASED SOLVENTS AND CLEANERS CAN DAMAGE THE RADIATOR END TANK SEALS AND CAUSE LEAKS. 4. Remove the upper transmission oil cooler fitting. NOTE: REMOVE ONLY ONE (1) TRANSMISSION OIL COOLER FITTING AT A TIME, OTHERWISE THE COOLER MAY DROP INTO THE RADIATOR. 5. Once the fitting is removed from the transmission oil cooler, verify that there is a gasket between the transmission oil cooler and the inside of the radiator tank. If there is no gasket, replace the radiator. If the gasket is in place, continue to Step 6. 6. Inspect the transmission oil cooler fitting threads for damage. If the threads are damaged, replace the radiator. If the threads show no sign of damage, continue to Step 7. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 6264 7. Install O-ring W705181-S on the transmission oil cooler fitting. Refer to Figures 2 and 3. CAUTION: THREAD SEALANT OR TAPE SHOULD NEVER BE USED ON THE THREADS OF THE TRANSMISSION OIL COOLER FITTING. THE USE OF SUCH MATERIALS WILL CREATE A LEAK PATH. 8. Making sure that the gasket between the transmission oil cooler and the inside of the radiator tank is still in place, reinstall the transmission oil cooler fitting. The fitting should be torqued to 38-45 N.m (28-33 lb-ft). NOTE:: DO NOT USE AIR TOOLS TO TORQUE THE TRANSMISSION OIL COOLER FITTING. USE A HAND-OPERATED TORQUE WRENCH ONLY. 9. Repeat Steps 2-8 for the other transmission oil cooler fitting. This fitting should also have the O-ring replaced even if it is not leaking. 10. Make sure that no radiator coolant has entered the transmission oil cooler. Reinstall the radiator in the vehicle following Workshop Manual procedure. 11. Verify that both the transmission and the engine cooling system have the proper fluid levels outlined in the Workshop Manual. PARTS INFORMATION LABOR OPERATION APPLICATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 6265 OTHER APPLICABLE ARTICLES: NONE SUPERCEDES: 99-4-6 WARRANTY STATUS OPERATION DESCRIPTION DEALER CODING OASIS CODES: 402000, 510000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 97410 > Feb > 97 > A/T - E4OD Cooler Bypass Valve Service Tip Transmission Cooler: All Technical Service Bulletins A/T - E4OD Cooler Bypass Valve Service Tip Article No. 97-4-10 02/17/97 TRANSMISSION - E4OD - COOLER BYPASS VALVE SERVICE DURING TRANSMISSION OVERHAUL - SERVICE TIP LIGHT TRUCK: 1997 ECONOLINE, EXPEDITION, F-150, F-250 LD ISSUE: E4OD transmissions have been equipped with an external Cooler Bypass Valve (CBV) (Figure 1) on some vehicles. The CBV allows some transmission fluid to bypass the transmission fluid coolers and return to the transmission sump during cold weather operation. This provides taster transmission fluid warm up and increased lube flow during cold weather operation. ACTION: The CBV must be removed and backflushed during a transmission overhaul or contamination may be reintroduced into the transmission, causing a repeat repair. Refer to the following text for details. Refer to the appropriate model Workshop Manual, Section 307-01, for CBV backflush procedure. When the CBV is removed, the four (4) sealing washers (Figure 1) must be replaced. These washers are available in the CBV Sealing Washers Kit (391933). These washers will also be added to the E4OD Soft Seal Kit (F0TZ-7153-A) in the future. CAUTION: THE CBV SEALING WASHERS AND/OR CASE FITTINGS CAN BE DAMAGED IF TOO MUCH BOLT TORQUE IS APPLIED TO THE CASE COOLER FITTINGS. IF REQUIRED APPLY A FORD-APPROVED THREAD SEALANT TO THE CASE FITTINGS AND TORQUE TO SPECIFICATION: ^ CASE INLET: 33-40 N.m (24-29 LB-FT) ^ CASE OUTLET: 27-33 N.m (20-24 LB-FT) NOTE: IF ENTIRE CBV ASSEMBLY REQUIRES REPLACEMENT, BE SURE TO REMOVE THE SHIPPING CAPS AND 0-RINGS PRIOR TO INSTALLATION OF THE NEW CBV ASSEMBLY. THE 0-RINGS ARE ONLY USED TO HOLD THE SEALING WASHERS IN PLACE FOR SHIPPING. NOTE: IF THE REMOVED CBV ASSEMBLY HAS AN 0-RING, REMOVE THE 0-RING PRIOR TO RE-INSTALLATION. CAUTION: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 97410 > Feb > 97 > A/T - E4OD Cooler Bypass Valve Service Tip > Page 6270 IF THE COOLER CBV ASSEMBLY IS INSTALLED WITH AN 0-RING, THE 0-RING MAY NOT ALLOW PROPER SEALING OF THE SEALING WASHERS AND MAY CAUSE A LEAK. The Cooler Bypass Valve Sealing Washers Kit contains the following: ^ Two (2) 391932-S100 Inlet Sealing Washers ^ Two (2) 391933-S100 Outlet Sealing Washers ^ One (1) Instruction Sheet (I.S. 7229) PART NUMBER PART NAME 391933 Cooler Bypass Valve Sealing Washers Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 503000, 504000, 510000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 962612 > Dec > 96 > Torque Converter - Cleaning and Replacement Guidelines Technical Service Bulletin # 962612 Date: 961216 Torque Converter - Cleaning and Replacement Guidelines Article No. 96-26-12 12/16/96 ^ TRANSAXLE - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSAXLE COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP ^ TRANSMISSION - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSMISSION COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP FORD: 1985-86 LTD 1985-88 EXP 1985-94 TEMPO 1985-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1985-86 MARQUIS 1985-87 LN7, LYNX 1985-92 MARK VII 1985-94 TOPAZ 1985-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-96 BRONCO 1985-97 ECONOLINE, F-150-350 SERIES, RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: Torque converter replacement guidelines and torque converter/transmission (or transaxle) cooling-system cleaning procedures are now available to reduce repeat repairs. ACTION: Refer to the following guideline to properly diagnose and service torque converters and to properly clean the torque converter and transmission cooling system using forward flushing/backflushing. For diagnosis, service and cleaning, refer to to the appropriate model/year Service Manual, Sections 07-01, 07-02, 03-03, 307-01, 307-02, or 303-03. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 962612 > Dec > 96 > Torque Converter - Cleaning and Replacement Guidelines > Page 6275 OASIS CODES: 501000, 502000, 503000, 504000 Diagnostic Procedure Prior to torque converter replacement, all diagnostic procedures must be followed. This is to prevent the unnecessary replacement of good torque converters. Only after a complete diagnostic evaluation can the decision be made to replace the torque converter. The normal diagnostic procedure is as follows: 1. Preliminary inspection. 2. Know and understand the customers concern. 3. Verify the concern: - Perform the Torque Converter Clutch Operation Test 4. Perform diagnostic procedures: a. Run On-Board Diagnostics - Repair all non-transmission-related Diagnostic Trouble Codes (DTCs) first. - Repair all transmission DTCs. - Rerun On-Board Diagnostic to verify repair. b. Perform Line Pressure Test c. Perform Stall Speed Test d. Diagnosis by Symptom Routines - Use the index to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed, diagnose and service as required, before servicing the torque converter. Replacement The torque converter must be replaced if one or more of the following statements are true: ^ A torque converter malfunction has been determined based on completed diagnostic procedures ^ A converter stud(s), impeller hub or bushing is damaged ^ If there is discoloration of the torque converter (due to overheating) ^ The torque converter is found to be out of specification when performing the following checks (as applicable): 1. Torque Converter One-way Clutch Check 2. End Play Check 3. Stator-to-Turbine Interference Check 4. Converter Leakage Check 5. Stator-to-Impeller Interference Check ^ If there is evidence of transmission assembly or fluid contamination due to the following failure modes: Torque converter Replacement Policy Failure Modes Major metallic failure Multiple clutches or clutch plate failures Sufficient component wear which results in metallic contamination Torque Converter & Transmission Cooling System Cleaning Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 962612 > Dec > 96 > Torque Converter - Cleaning and Replacement Guidelines > Page 6276 When the torque converter is replaced, the following actions must take place: 1. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 2. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All Cooler By-Pass Valves (CBV), it equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 4. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. If the torque converter is not being replaced, the following actions must take place: 1. The torque convener must be thoroughly cleaned: a. Torque converters with drain plugs can be cleaned using the Rotunda Torque Converter Cleaner Follow the instructions included with the equipment. b. Torque converters without drain plugs can be cleaned by hand. Partially fill the converter using clean transmission fluid (as recommended for the particular transmission). Hand agitate the converter and then thoroughly drain the fluid. Refill with new fluid, specified for the transmission, and reinstall. 2. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 4. All Cooler By-Pass Valves (CBV), if equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 5. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. Required Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Cooler: > 03-14-8 > Jul > 03 > A/T - Cooler Flushing Service Tips Transmission Cooler: All Technical Service Bulletins A/T - Cooler Flushing Service Tips Article No. 03-14-8 07/21/03 TRANSMISSION - NEW TRANSMISSION COOLER FLUSHER - SERVICE TIPS FORD: 1992-1997 CROWN VICTORIA, PROBE, THUNDERBIRD 1992-2003 ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1992-1996 BRONCO 1992-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1992-1999 F-250 LD 1992-2003 ECONOLINE, EXPLORER, F-150, RANGER 1995-2003 WINDSTAR 1997-2003 EXPEDITION 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1992-1997 TOWN CAR 1992-2002 CONTINENTAL 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD 2003 AVIATOR MERCURY: 1992-1997 COUGAR, GRAND MARQUIS 1992-2000 TRACER 1992-2003 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER This article supersedes TSB 00-1-5. ISSUE The number one cause for repeat transmission repairs is that contamination from the transmission cooler system (lines and tank) will work their way back into the rebuilt or new transmission. For this reason a new transmission cooler flusher has been released, "Turbo-Tank Heated Cooler Line Flusher" Rotunda Tool number 22-00001. ACTION The transmission cooling system (cooler and lines) MUST be flushed every time the transmission is overhauled or replaced in order to minimize the likelihood of repeat repairs. The use of this new "Turbo-Tank Heated Cooler Line Flusher" (222-00001) is the most effective way to remove contamination from its cooling system. Refer to the following Service Procedure and Equipment instructions (supplied with the "Turbo-Tank Heated Cooler Line Flusher"). SERVICE PROCEDURE Prior methods of cooler flushing have not obtained the level of cooler cleaning and contaminant removal that is required to prevent repeat repairs. The "Turbo-Tank Heated Cooler Line Flusher" uses heated Automatic Transmission Fluid (ATF) and a pulsating action to loosen system contamination. Previous equipment used solvents to clean & flush coolers, lines and torque-converters. There are 2 issues with this method: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Cooler: > 03-14-8 > Jul > 03 > A/T - Cooler Flushing Service Tips > Page 6282 ^ Residual solvent contamination can cause damage to friction bonding materials within the transmission (Clutches and Bands). ^ Lack of fluid heating and agitation prevents this method from completely removing contamination from lines, in-radiator coolers and auxiliary coolers. Aerosol Solvents should never be used for several reasons. ^ They do not provide the volume necessary to remove heavy contaminants. ^ They evaporate quickly and essentially leave contaminants in pockets, bends, or wherever they are as the solvent dries. NOTE YOU MUST IDENTIFY THE RETURN COOLER LINE TO START THE BACK FLUSHING PROCEDURE. A quick way to identify the return cooler line (fluid coming out of the cooler and returning to the transmission) is to locate the return cooler line fitting on the transmission case. Refer to the following lists: Rear Wheel Drive ^ TORQSHIFT, 4R100, E40D, C6 - The REAR transmission case filling receives the return line. ^ 4R70W, AODE, AOD - The TOP transmission case filling receives the return line. ^ A4LD, 4R44/55E, 5R55E, 5R55N, 5R55W, 5R55S - The TOP transmission case filling receives the return line. Front Wheel Drive ^ CD4E - The REAR or Pump End transaxle case fitting receives the return line. ^ 4F27E - The REAR or Cover End transaxle case fitting receives the return line. ^ AXOD, AXODE, AX4S, AX4N, 4F50N - The BOTTOM transaxle cooler line fitting receives the return line. NOTE IF AN IN-LINE FILTER HAS BEEN INSTALLED IN THE COOLER LINE, IT MUST BE REMOVED BEFORE FLUSHING THE COOLER OR COOLER LINES. Purge the cooler and cooler line before flushing: Located on the "Turbo-Tank Heated Cooler Line Flusher" is a fluid transfer and purge valve. This valve can be used to purge the cooler and cooler lines of contaminated fluid before starting the back flush procedure of the fluid cooling system (refer to step 5a of this Service Procedure or Equipment instructions, supplied with the "Turbo-Tank Heated Cooler Line Flusher"). Flush Procedure 1. Check and top off fluid level of the "Turbo-Tank Heated Cooler Line Flusher" tank with transmission fluid. 2. Allow the fluid in the flusher 15-30 minutes to heat up to 140° F (60° C) before using. 3. Install line adapters into the transmission cooler lines. 4. Attach the flusher's blue line to the transmission return cooler line quick disconnect. 5. Attach the flusher's red line to the transmission outlet cooler line quick disconnect. a. Follow equipment instructions, to purge cooler lines and cooler prior to starting flushing procedure (using factory installed purge valve and clear hose on "Turbo-Tank Heated Cooler Line Flusher"). 6. Allow the cooling system to back-flush for 10-15 minutes, then flush the cooler in a forward/normal flow direction for an additional 10-15 minutes. For ordering information on this new "Turbo-Tank Heated Cooler Line Flusher" (222-00001), contact Rotunda at 800-ROTUNDA (800-768-8632 or outside U.S. 262-656-5805). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Cooler: > 03-14-8 > Jul > 03 > A/T - Cooler Flushing Service Tips > Page 6283 CAUTION THIS FLUSHER CANNOT BE USED TO FLUSH COOLERS ON VEHICLES EQUIPPED WITH THE TEMPERATURE BYPASS-TYPE TRANSMISSION COOLER CURRENTLY FOUND IN 1998-2003 CROWN VICTORIA, GRAND MARQUIS, AND TOWN CAR VEHICLES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-1-5 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Cooler: > 97410 > Feb > 97 > A/T - E4OD Cooler Bypass Valve Service Tip Transmission Cooler: All Technical Service Bulletins A/T - E4OD Cooler Bypass Valve Service Tip Article No. 97-4-10 02/17/97 TRANSMISSION - E4OD - COOLER BYPASS VALVE SERVICE DURING TRANSMISSION OVERHAUL - SERVICE TIP LIGHT TRUCK: 1997 ECONOLINE, EXPEDITION, F-150, F-250 LD ISSUE: E4OD transmissions have been equipped with an external Cooler Bypass Valve (CBV) (Figure 1) on some vehicles. The CBV allows some transmission fluid to bypass the transmission fluid coolers and return to the transmission sump during cold weather operation. This provides taster transmission fluid warm up and increased lube flow during cold weather operation. ACTION: The CBV must be removed and backflushed during a transmission overhaul or contamination may be reintroduced into the transmission, causing a repeat repair. Refer to the following text for details. Refer to the appropriate model Workshop Manual, Section 307-01, for CBV backflush procedure. When the CBV is removed, the four (4) sealing washers (Figure 1) must be replaced. These washers are available in the CBV Sealing Washers Kit (391933). These washers will also be added to the E4OD Soft Seal Kit (F0TZ-7153-A) in the future. CAUTION: THE CBV SEALING WASHERS AND/OR CASE FITTINGS CAN BE DAMAGED IF TOO MUCH BOLT TORQUE IS APPLIED TO THE CASE COOLER FITTINGS. IF REQUIRED APPLY A FORD-APPROVED THREAD SEALANT TO THE CASE FITTINGS AND TORQUE TO SPECIFICATION: ^ CASE INLET: 33-40 N.m (24-29 LB-FT) ^ CASE OUTLET: 27-33 N.m (20-24 LB-FT) NOTE: IF ENTIRE CBV ASSEMBLY REQUIRES REPLACEMENT, BE SURE TO REMOVE THE SHIPPING CAPS AND 0-RINGS PRIOR TO INSTALLATION OF THE NEW CBV ASSEMBLY. THE 0-RINGS ARE ONLY USED TO HOLD THE SEALING WASHERS IN PLACE FOR SHIPPING. NOTE: IF THE REMOVED CBV ASSEMBLY HAS AN 0-RING, REMOVE THE 0-RING PRIOR TO RE-INSTALLATION. CAUTION: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Cooler: > 97410 > Feb > 97 > A/T - E4OD Cooler Bypass Valve Service Tip > Page 6288 IF THE COOLER CBV ASSEMBLY IS INSTALLED WITH AN 0-RING, THE 0-RING MAY NOT ALLOW PROPER SEALING OF THE SEALING WASHERS AND MAY CAUSE A LEAK. The Cooler Bypass Valve Sealing Washers Kit contains the following: ^ Two (2) 391932-S100 Inlet Sealing Washers ^ Two (2) 391933-S100 Outlet Sealing Washers ^ One (1) Instruction Sheet (I.S. 7229) PART NUMBER PART NAME 391933 Cooler Bypass Valve Sealing Washers Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 503000, 504000, 510000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Cooler: > 962612 > Dec > 96 > Torque Converter - Cleaning and Replacement Guidelines Technical Service Bulletin # 962612 Date: 961216 Torque Converter - Cleaning and Replacement Guidelines Article No. 96-26-12 12/16/96 ^ TRANSAXLE - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSAXLE COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP ^ TRANSMISSION - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSMISSION COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP FORD: 1985-86 LTD 1985-88 EXP 1985-94 TEMPO 1985-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1985-86 MARQUIS 1985-87 LN7, LYNX 1985-92 MARK VII 1985-94 TOPAZ 1985-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-96 BRONCO 1985-97 ECONOLINE, F-150-350 SERIES, RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: Torque converter replacement guidelines and torque converter/transmission (or transaxle) cooling-system cleaning procedures are now available to reduce repeat repairs. ACTION: Refer to the following guideline to properly diagnose and service torque converters and to properly clean the torque converter and transmission cooling system using forward flushing/backflushing. For diagnosis, service and cleaning, refer to to the appropriate model/year Service Manual, Sections 07-01, 07-02, 03-03, 307-01, 307-02, or 303-03. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Cooler: > 962612 > Dec > 96 > Torque Converter - Cleaning and Replacement Guidelines > Page 6293 OASIS CODES: 501000, 502000, 503000, 504000 Diagnostic Procedure Prior to torque converter replacement, all diagnostic procedures must be followed. This is to prevent the unnecessary replacement of good torque converters. Only after a complete diagnostic evaluation can the decision be made to replace the torque converter. The normal diagnostic procedure is as follows: 1. Preliminary inspection. 2. Know and understand the customers concern. 3. Verify the concern: - Perform the Torque Converter Clutch Operation Test 4. Perform diagnostic procedures: a. Run On-Board Diagnostics - Repair all non-transmission-related Diagnostic Trouble Codes (DTCs) first. - Repair all transmission DTCs. - Rerun On-Board Diagnostic to verify repair. b. Perform Line Pressure Test c. Perform Stall Speed Test d. Diagnosis by Symptom Routines - Use the index to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed, diagnose and service as required, before servicing the torque converter. Replacement The torque converter must be replaced if one or more of the following statements are true: ^ A torque converter malfunction has been determined based on completed diagnostic procedures ^ A converter stud(s), impeller hub or bushing is damaged ^ If there is discoloration of the torque converter (due to overheating) ^ The torque converter is found to be out of specification when performing the following checks (as applicable): 1. Torque Converter One-way Clutch Check 2. End Play Check 3. Stator-to-Turbine Interference Check 4. Converter Leakage Check 5. Stator-to-Impeller Interference Check ^ If there is evidence of transmission assembly or fluid contamination due to the following failure modes: Torque converter Replacement Policy Failure Modes Major metallic failure Multiple clutches or clutch plate failures Sufficient component wear which results in metallic contamination Torque Converter & Transmission Cooling System Cleaning Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Cooler: > 962612 > Dec > 96 > Torque Converter - Cleaning and Replacement Guidelines > Page 6294 When the torque converter is replaced, the following actions must take place: 1. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 2. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All Cooler By-Pass Valves (CBV), it equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 4. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. If the torque converter is not being replaced, the following actions must take place: 1. The torque convener must be thoroughly cleaned: a. Torque converters with drain plugs can be cleaned using the Rotunda Torque Converter Cleaner Follow the instructions included with the equipment. b. Torque converters without drain plugs can be cleaned by hand. Partially fill the converter using clean transmission fluid (as recommended for the particular transmission). Hand agitate the converter and then thoroughly drain the fluid. Refill with new fluid, specified for the transmission, and reinstall. 2. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 4. All Cooler By-Pass Valves (CBV), if equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 5. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. Required Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Locations > With Auxiliary Cooler Transmission Cooler: Locations With Auxiliary Cooler Part 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Locations > With Auxiliary Cooler > Page 6297 Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Locations > With Auxiliary Cooler > Page 6298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Locations > Page 6299 Transmission Cooler: Description and Operation All vehicles with automatic transmissions are equipped with an integral transmission fluid cooler. The integral transmission fluid cooler is contained inside of the radiator outlet tank and cannot be repaired separately. Some vehicles are equipped with an optional auxiliary transmission fluid cooler that is mounted in front of the radiator. In operation, transmission fluid travels from the transmission to the auxiliary transmission fluid cooler, if equipped, to the integral transmission fluid cooler then back to the transmission. The integral transmission fluid cooler transfers heat from the transmission fluid to the engine coolant. The auxiliary transmission fluid cooler transfers heat from the transmission fluid to outside air. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Transmission Cooler: Initial Inspection and Diagnostic Overview When fluid leakage is found at any of the transmission fluid cooling components, the component must be replaced. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6302 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6303 Transmission Cooler: Component Tests and General Diagnostics NOTE: The transmission linkage/cable adjustment, fluid level and line pressure must be within specification before performing this test. 1. Remove the fluid level indicator from the fluid filler tube. 2. Place a funnel in the fluid filler tube. 3. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 4. Disconnect the cooler return tube (rear fitting) from the transmission cooler bypass valve (CBV). 5. Connect one end of a hose to the cooler return tube and route the other end of the hose up to a point where it can be inserted into the funnel at the fluid filler tube. 6. Remove the supports and lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. 7. Insert the end of a hose into the funnel. 8. Start the engine and run at idle with the transmission in the neutral range. 9. When the fluid flowing from the hose is all liquid, an adequate amount of fluid should be observed, approximately 1.0 L (1.057 quarts) delivered in 30 seconds. If adequate flow is observed, the test is completed. 10. If the flow is not adequate, stop the engine. Disconnect the hose from the cooler return tube and connect it to the converter-out tube fitting (front fitting at the transmission cooler bypass valve). 11. Repeat Steps 7 and 8. If the flow is now adequate, further diagnosis of the transmission fluid cooler. If the flow is not adequate, repair or replace the pump, the converter assembly, or both. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Auxiliary Transmission Cooler: Service and Repair Auxiliary REMOVAL 1. Remove the front skid plate. (1) Remove the front skid plate bolts. (2) Remove the front skid plate. 2. Place a drain pan under the auxiliary transmission fluid cooler. 3. Remove the auxiliary transmission fluid cooler. (1) Disconnect the two auxiliary transmission fluid cooler tubes. (2) Remove the four auxiliary transmission fluid cooler bolts. (3) Remove the auxiliary transmission fluid cooler. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Auxiliary > Page 6306 INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Auxiliary > Page 6307 Transmission Cooler: Service and Repair Cooler Bypass Valve Cooler Bypass Valve cleaning 1. Remove the cooler bypass valve (CBV). 2. Using the Torque Converter/Oil Cooler Cleaner and adapter kit flush the transmission CBV assembly. 3. Plug the CBV front fitting with a 13 mm x 1.5 mm threaded plug. CAUTION: Make sure the CBV is in the solvent tank before turning on the solvent. Also, make sure the fitting is pointed down so solvent does not spray upward out of the tank. NOTE: The solvent pressure must be a minimum of 50 psi to overcome the valve inside the cooler bypass tube and let solvent flow. Do not exceed 90 psi. 4. Place a 1/2 inch flat washer and connect the cleaner pressure line over the fitting that screws into the case out hole. 5. Place the CBV valve into the solvent tank. Regulate the solvent pressure to between 50 and 90 psi. Turn on the solvent and circulate for 5 minutes. NOTE: The Torque Converter/Oil Cooler Cleaner can be switched on and off to help dislodge the contaminants. 6. Disconnect all rubber hoses from the CBV. 7. Use regulated compressed air to purge the CBV of solvent. Remove the plug from the CBV. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Auxiliary > Page 6308 8. Install the cooler bypass valve. Removal and Installation NOTE: MERCON Automatic Transmission Fluid is being replaced by MERCON V as a service fluid. REMOVAL 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Remove the front cooler tube, from the front cooler bypass valve (CBV)fitting. 3. Remove the rear cooler tube, from the rear CBV fitting. 4. Remove the front CBV bolt. NOTE: The two Viton coated washers can fall out during removal of the front CBV bolt. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Auxiliary > Page 6309 5. Remove the rear CBV bolt. NOTE: The two viton washers can fall out during removal of the rear CBV bolt. 6. Remove the CBV. INSTALLATION 1. Examine the viton coated washers for damage. Replace the washers as needed. CAUTION: Make sure the 4 viton coated washers are on the cooler nuts and the CBV washers are in place. Do not over tighten. 2. Using Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specifications, coat the CBV bolt threads. 3. Install the CBV fitting bolts. CAUTION: - Make sure the cooler bypass valve (CBV) is properly backflushed. Use dry compressed air to remove solvent. - If the CBV bolt is over-tightened the viton coated washers can be damaged, causing a transmission fluid leak. NOTE: - The CBV has a check ball and will only allow flow in one direction. - Align the two viton coated washers, while assembling the rear CBV fining. 4. Tighten the cooler tube nuts. 5. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Auxiliary > Page 6310 6. Fill the transmission with Motorcraft MERCON or MERCON V Automatic Transmission Fluid or equivalent meeting Ford specification. Check for proper operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Auxiliary > Page 6311 Transmission Cooler: Service and Repair Flushing and Cleaning 1. Conduct backflushing with a Torque Converter/Oil Cooler Cleaner 014-00028 or equivalent. Test your equipment to make sure that a vigorous fluid flow is present before proceeding. Replace the system filter if flow is weak or contaminated. 2. To aid in attaching the cleaner to the transmission steel cooler lines, connect two additional rubber hoses to the transmission end of the steel transmission cooler lines as described below. Connect the cleaner tank pressure line to the steel transmission cooler return line (top line at the transmission case fitting). - Connect a tank return hose to the steel transmission cooler pressure line (bottom line at the transmission case fitting). Place the outlet end of this hose in the solvent tank reservoir. 3. Turn on solvent pump and allow the solvent to circulate a minimum of 5 minutes (cycling switch on and off will help dislodge contaminants in cooler system). 4. Switch off the solvent pump and disconnect the solvent pressure hose from the transmission cooler return line. 5. Use compressed air to blow out the cooler(s) and lines (blow air into the transmission cooler return line) until all solvent is removed. 6. Remove the rubber return hose from the remaining steel cooler line. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Indicator - A/T > Component Information > Testing and Inspection Transmission Mode Indicator - A/T: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6319 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6320 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6321 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6322 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6323 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6324 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6325 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6326 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6327 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6328 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6329 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6330 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6331 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6332 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6333 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6334 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6335 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6336 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6337 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6338 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6339 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6340 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6341 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6342 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6343 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6344 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6345 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6346 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6347 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6348 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6349 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6350 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6351 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6352 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6353 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6354 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6355 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6356 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6357 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6358 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6359 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6360 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6361 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6362 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6363 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6364 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6365 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6366 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6367 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6368 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6369 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6370 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6371 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6372 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6373 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6374 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6375 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6376 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6377 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6378 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6379 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6380 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6381 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6382 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6383 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6384 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6385 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6386 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6387 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6388 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6389 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6390 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6391 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6392 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6393 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6394 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6395 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6396 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6397 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6398 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6399 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6400 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6401 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6402 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6403 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6404 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6405 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6406 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6407 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6408 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6409 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6410 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6411 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6412 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6413 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Page 6414 Transmission Mount: Specifications TORQUE SPECIFICATIONS Transmission Mount Nuts ........................................................................................................................................................ 98-132 Nm (73-97 ft. lbs.) Transmission Mount Bolts ....................................................................................................................................................... 87-110 Nm (64-81 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > New Digital Transmission Range Sensor Service Tip Transmission Position Switch/Sensor: Technical Service Bulletins New Digital Transmission Range Sensor - Service Tip Article No. 96-24-10 11/18/96 TRANSMISSION - E40D - 4R70W - 4R44E - 5R55E - NEW DIGITAL TRANSMISSION RANGE SENSOR - DIAGNOSIS SERVICE TIP LINCOLN-MERCURY: 1997 MARK VIII LIGHT TRUCK: 1997 AEROSTAR, ECONOLINE, EXPEDITION, EXPLORER, F-150, F-250, MOUNTAINEER ISSUE: Beginning with Job 1 1997, some vehicles will be equipped with a new Digital Transmission Range (DTR) sensor. The DTR sensor is located on the outside of the transmission (Figure 1) at the outer manual lever. ACTION: Refer to the following text to properly diagnose a concern with the DTR sensor. The new DTR sensor completes the start circuit in "Park" and "Neutral," the backup lamp circuit in "Reverse" and the neutral sense circuit (4X4 only) in "Neutral." The DTR sensor also opens/closes a set of four (4) switches that are monitored by the Powertrain Control Module (PCM) to determine the position of the transmission manual lever. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > New Digital Transmission Range Sensor Service Tip > Page 6419 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > New Digital Transmission Range Sensor Service Tip > Page 6420 To properly diagnose the DTR sensor, use the NGS, Rotunda Transmission Tester with TR/MLP Cable "E" (Figure 2) and the new DTR Sensor Overlay (Figure 4), while following the procedures outlined in the appropriate model 1997 Service Manual, Section 07-01 or appropriate model 1997 Workshop Manual, Section 307-01. The new DTR Sensor Overlay (007-00131) and updated Tester Manual was sent to all dealers in August 1996. The TR/MLP Cable "E" (007-00111) was sent to all dealers in June 1995 (refer to TSB 95-19-7). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > New Digital Transmission Range Sensor Service Tip > Page 6421 When using Cable "E" (Figure 3) to diagnose the DTR sensor, the slide switch must be in the "Digital" position and the "Black" 12-pin connector installed on the sensor. Having the slide switch in the incorrect position or using the incorrect 12-pin connector will result in misdiagnosis and possible replacement of a good component. For diagnosis of the DTR sensor, always refer to the appropriate model 1997 Service Manual, Section 07.01 or appropriate model 1997 Workshop Manual, Section 3O7-01 for proper procedure and required equipment. OTHER APPLICABLE ARTICLES: 95-19-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 503000, 503300, 504000, 601300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 6422 Transmission Position Switch/Sensor: Specifications TORQUE SPECIFICATIONS DTR Sensor Bolts ................................................................................................................................ ..................................... 7-10 Nm (62-89 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 6423 Transmission Position Switch/Sensor: Locations Transmission View The Digital Transmission Range Sensor is located at left side of the automatic transmission. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 6424 Digital Transmission Range Sensor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 6425 Transmission Position Switch/Sensor: Adjustments NOTE: Use Digital Transmission Range (DTR) Sensor Alignment Tool to align both TR and DTR sensors. 1. Raise and support vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Disconnect the manual lever shift control cable. 3. Disconnect the TR or DTR electrical connector. 4. Remove the manual control lever. (1) Remove the nut. (2) Remove the lever. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. 5. Loosen the TR or DTR bolts. 6. Use DTR sensor alignment tool, to align the DTR or TR sensor slots. NOTE: Manual shift lever must be in the neutral position. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 6426 7. Tighten the DTR or TR sensor bolts. 8. Install the manual control lever. (1) Position the manual control lever. (2) Install a new manual lever shaft outer nut. 9. With the manual lever in overdrive connect the shift lever control cable. 10. Install the DTR sensor electrical connector. 11. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications TORQUE SPECIFICATIONS Output Shaft Speed (OSS) Sensor Bolt .......................................................................................................................................... 8-16 Nm (6-12 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 6430 Transmission Speed Sensor: Locations Transmission View The Output Shaft Speed Sensor is located at left side of transmission. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 6431 Output Shaft Speed Sensor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 98-9-20 > May > 98 > A/T - E4OD 4-1 Downshift During Forced 4-2 Downshift Valve Body: Customer Interest A/T - E4OD 4-1 Downshift During Forced 4-2 Downshift Article No. 98-9-20 05/11/98 TRANSMISSION - E4OD - DOWNSHIFT DURING A FORCED 4-2 DOWNSHIFT BETWEEN 88-105 KM/H (55-65 MPH) - VEHICLES BUILT THROUGH 12/22/97 LIGHT TRUCK: 1997-98 ECONOLINE, EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR ISSUE Some vehicles may experience a 4-1 downshift when performing a forced 4-2 downshift (kickdown) between 88-105 km/h (55-65 mph) causing the engine rpm to increase higher than expected. This may be caused by internal leakage of fluid between the hydraulic circuits in the transmission case worm trail between the separator plate gasket and transmission case. ACTION Perform normal diagnostics as outlined in the appropriate Workshop Manual. If the concern is still present, replace the separator plate and gaskets. Refer to the Application Chart below and the appropriate Workshop Manual for replacement procedures. PART NUMBER PART NAME F8UZ-7A008-CA Separator Plate F81Z-7A008-EA Separator Plate F81Z-7C155-AA Gasket F81Z-7D100-AB Gasket OTHER APPLICABLE ARTICLES: 98-9-21 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 98O92OA Replace Separator Plate 2.1 Hrs. And Gasket DEALER CODING CONDITION BASIC PART NO. CODE 7A008, 7D100 42 OASIS CODES: 502000, 504000, 590000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 97-13-23 > Jun > 97 > A/T - E4OD Slip/Bump on 1st to 2nd Gear Upshifts Valve Body: Customer Interest A/T - E4OD Slip/Bump on 1st to 2nd Gear Upshifts Article No. 97-13-23 06/23/97 ^ TRANSMISSION - E40D - INCORRECT SEPARATOR PLATE - 4X4 VEHICLES BUILT FROM 4/18/97 THROUGH 4/21/97 ^ TRANSMISSION - E40D - SLIP/BUMP 1-2 UPSHIFTS - 4X4 VEHICLES BUILT FROM 4/18/97 THROUGH 4/21/97 LIGHT TRUCK: 1997 EXPEDITION, F-150 ISSUE: Soft/drawn out and/or slip/bump 1-2 upshifts may occur on some vehicles. This may be caused by the E40D transmission being built with the wrong valve body separator plate. ACTION: Confirm the vehicle build dates are from 4/18/97 through 4/21/97, and transmission build date is 7D15 with serial numbers between 00012500 and 00012855. When confirmation is made, replace transmission with an exchange unit, or if exchange is not available replace the Separator Plate and mating gaskets. Refer to the following Service Procedure for details. SERVICE PROCEDURE For vehicles that do not fit the following description, follow all the normal diagnostics as outlined in the appropriate Workshop Manual and service as required. Refer to the Parts Catalog for proper part usage. 1. Verify the following: ^ Concern ^ Vehicle application ^ Vehicle build dates ^ Transmission build date ^ Transmission serial number 2. Call (800) 543-8742 to exchange transmission. 3. If an exchange unit is not available and vehicle fits the description listed in Step 1, replace the separator plate and mating gaskets. a. Remove transmission pan, main controls, accumulator body, and solenoid body. b. Remove the separator plate and both gaskets, discard plate and gaskets. CAUTION: SOME OF THESE VEHICLES MAY EXPERIENCE INTERNAL DAMAGE. THE TRANSMISSION MAY NEED TO BE REMOVED, DISASSEMBLED AND REPAIRED TO PREVENT A REPEAT REPAIR LATER. 4. If the transmission fluid shows signs of overheating or breakdown, remove the transmission, and repair as required. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 97-13-23 > Jun > 97 > A/T - E4OD Slip/Bump on 1st to 2nd Gear Upshifts > Page 6444 5. Install new Separator Plate (F7TZ-7A008-AA) (refer to Figure 1 for separator plate identification) and the mating gaskets: ^ Separator Plate-To-Case Gasket (F6TZ-7C155-A) ^ Separator Plate-To-Valve Body Gasket (F6TZ-7D100-A) NOTE: FOLLOW ALL NORMAL SERVICE PROCEDURES AS OUTLINED IN THE 1997 F-150 OR EXPEDITION WORKSHOP MANUAL. CAUTION: FLUSH ALL COOLERS, COOLER LINES, AND COOLER BYPASS VALVE PRIOR TO INSTALLING NEW EXCHANGE OR REPAIRED TRANSMISSION. PART NUMBER PART NAME F7TZ-7A008-AA Valve Body Separator Plate F6TZ-7C155-A Separator Plate-To-Case Gasket F6TZ-7D100-A Separator Plate-To-Valve Body Gasket OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971323A Replace Transmission Or Refer Separator Plate To SLTS Manual DEALER CODING CONDITION BASIC PART NO. CODE 7A008 12 OASIS CODES: 501000, 502000, 503000, 504000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 98-16-8 > Aug > 98 > A/T - Main Controls/Separator Plate/Gaskets Usage Valve Body: All Technical Service Bulletins A/T - Main Controls/Separator Plate/Gaskets Usage Article No. 98-16-8 08/17/98 TRANSMISSION - E4OD/4R100 - 1989-99 - MAIN CONTROLS, SEPARATOR PLATES AND SEPARATOR PLATE GASKETS USAGE CHART LIGHT TRUCK: 1989-96 BRONCO, F-150 1989-97 F SUPER DUTY, F-250 HD 1989-98 ECONOLINE, F-250 LD, F-35O 1997-98 EXPEDITION, F-150 1998 NAVIGATOR 1999 SUPER DUTY F SERIES Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 98-16-8 > Aug > 98 > A/T - Main Controls/Separator Plate/Gaskets Usage > Page 6450 This TSB article is being republished in its entirety to revise Figure 1. ISSUE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 98-16-8 > Aug > 98 > A/T - Main Controls/Separator Plate/Gaskets Usage > Page 6451 The Chart has been developed to assist in showing the complexity and compatibility of main controls, separator plates, and plate gaskets used for E4OD/4R100 transmissions. ACTION Refer to the Usage Chart for information showing the compatibility of main controls, separator plates, and plate gaskets. This TSB should not be used in place of the Parts Catalog. NOTE TO VERIFY CORRECT GASKET USAGE, REFER TO FIGURE 1 TO IDENTIFY THE SEPARATOR PLATE I.D. NOTCHES. THEN REFER TO THE CHART TO SEE WHICH GASKETS ARE COMPATIBLE WITH THE MAIN CONTROLS AND SEPARATOR PLATES BEING USED. CAUTION MIXING COMPONENTS OTHER THAN THOSE LISTED MAY CAUSE SHIFT CONCERNS AND/OR DAMAGE TO THE TRANSMISSION. REFER TO THE PARTS CATALOG FOR PROPER USAGE BY MODEL AND YEAR. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-9-21 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 504000, 590000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 98-9-20 > May > 98 > A/T - E4OD 4-1 Downshift During Forced 4-2 Downshift Valve Body: All Technical Service Bulletins A/T - E4OD 4-1 Downshift During Forced 4-2 Downshift Article No. 98-9-20 05/11/98 TRANSMISSION - E4OD - DOWNSHIFT DURING A FORCED 4-2 DOWNSHIFT BETWEEN 88-105 KM/H (55-65 MPH) - VEHICLES BUILT THROUGH 12/22/97 LIGHT TRUCK: 1997-98 ECONOLINE, EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR ISSUE Some vehicles may experience a 4-1 downshift when performing a forced 4-2 downshift (kickdown) between 88-105 km/h (55-65 mph) causing the engine rpm to increase higher than expected. This may be caused by internal leakage of fluid between the hydraulic circuits in the transmission case worm trail between the separator plate gasket and transmission case. ACTION Perform normal diagnostics as outlined in the appropriate Workshop Manual. If the concern is still present, replace the separator plate and gaskets. Refer to the Application Chart below and the appropriate Workshop Manual for replacement procedures. PART NUMBER PART NAME F8UZ-7A008-CA Separator Plate F81Z-7A008-EA Separator Plate F81Z-7C155-AA Gasket F81Z-7D100-AB Gasket OTHER APPLICABLE ARTICLES: 98-9-21 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 98O92OA Replace Separator Plate 2.1 Hrs. And Gasket DEALER CODING CONDITION BASIC PART NO. CODE 7A008, 7D100 42 OASIS CODES: 502000, 504000, 590000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 97-13-23 > Jun > 97 > A/T - E4OD Slip/Bump on 1st to 2nd Gear Upshifts Valve Body: All Technical Service Bulletins A/T - E4OD Slip/Bump on 1st to 2nd Gear Upshifts Article No. 97-13-23 06/23/97 ^ TRANSMISSION - E40D - INCORRECT SEPARATOR PLATE - 4X4 VEHICLES BUILT FROM 4/18/97 THROUGH 4/21/97 ^ TRANSMISSION - E40D - SLIP/BUMP 1-2 UPSHIFTS - 4X4 VEHICLES BUILT FROM 4/18/97 THROUGH 4/21/97 LIGHT TRUCK: 1997 EXPEDITION, F-150 ISSUE: Soft/drawn out and/or slip/bump 1-2 upshifts may occur on some vehicles. This may be caused by the E40D transmission being built with the wrong valve body separator plate. ACTION: Confirm the vehicle build dates are from 4/18/97 through 4/21/97, and transmission build date is 7D15 with serial numbers between 00012500 and 00012855. When confirmation is made, replace transmission with an exchange unit, or if exchange is not available replace the Separator Plate and mating gaskets. Refer to the following Service Procedure for details. SERVICE PROCEDURE For vehicles that do not fit the following description, follow all the normal diagnostics as outlined in the appropriate Workshop Manual and service as required. Refer to the Parts Catalog for proper part usage. 1. Verify the following: ^ Concern ^ Vehicle application ^ Vehicle build dates ^ Transmission build date ^ Transmission serial number 2. Call (800) 543-8742 to exchange transmission. 3. If an exchange unit is not available and vehicle fits the description listed in Step 1, replace the separator plate and mating gaskets. a. Remove transmission pan, main controls, accumulator body, and solenoid body. b. Remove the separator plate and both gaskets, discard plate and gaskets. CAUTION: SOME OF THESE VEHICLES MAY EXPERIENCE INTERNAL DAMAGE. THE TRANSMISSION MAY NEED TO BE REMOVED, DISASSEMBLED AND REPAIRED TO PREVENT A REPEAT REPAIR LATER. 4. If the transmission fluid shows signs of overheating or breakdown, remove the transmission, and repair as required. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 97-13-23 > Jun > 97 > A/T - E4OD Slip/Bump on 1st to 2nd Gear Upshifts > Page 6460 5. Install new Separator Plate (F7TZ-7A008-AA) (refer to Figure 1 for separator plate identification) and the mating gaskets: ^ Separator Plate-To-Case Gasket (F6TZ-7C155-A) ^ Separator Plate-To-Valve Body Gasket (F6TZ-7D100-A) NOTE: FOLLOW ALL NORMAL SERVICE PROCEDURES AS OUTLINED IN THE 1997 F-150 OR EXPEDITION WORKSHOP MANUAL. CAUTION: FLUSH ALL COOLERS, COOLER LINES, AND COOLER BYPASS VALVE PRIOR TO INSTALLING NEW EXCHANGE OR REPAIRED TRANSMISSION. PART NUMBER PART NAME F7TZ-7A008-AA Valve Body Separator Plate F6TZ-7C155-A Separator Plate-To-Case Gasket F6TZ-7D100-A Separator Plate-To-Valve Body Gasket OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971323A Replace Transmission Or Refer Separator Plate To SLTS Manual DEALER CODING CONDITION BASIC PART NO. CODE 7A008 12 OASIS CODES: 501000, 502000, 503000, 504000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 98-16-8 > Aug > 98 > A/T - Main Controls/Separator Plate/Gaskets Usage Valve Body: All Technical Service Bulletins A/T - Main Controls/Separator Plate/Gaskets Usage Article No. 98-16-8 08/17/98 TRANSMISSION - E4OD/4R100 - 1989-99 - MAIN CONTROLS, SEPARATOR PLATES AND SEPARATOR PLATE GASKETS USAGE CHART LIGHT TRUCK: 1989-96 BRONCO, F-150 1989-97 F SUPER DUTY, F-250 HD 1989-98 ECONOLINE, F-250 LD, F-35O 1997-98 EXPEDITION, F-150 1998 NAVIGATOR 1999 SUPER DUTY F SERIES Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 98-16-8 > Aug > 98 > A/T - Main Controls/Separator Plate/Gaskets Usage > Page 6466 This TSB article is being republished in its entirety to revise Figure 1. ISSUE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 98-16-8 > Aug > 98 > A/T - Main Controls/Separator Plate/Gaskets Usage > Page 6467 The Chart has been developed to assist in showing the complexity and compatibility of main controls, separator plates, and plate gaskets used for E4OD/4R100 transmissions. ACTION Refer to the Usage Chart for information showing the compatibility of main controls, separator plates, and plate gaskets. This TSB should not be used in place of the Parts Catalog. NOTE TO VERIFY CORRECT GASKET USAGE, REFER TO FIGURE 1 TO IDENTIFY THE SEPARATOR PLATE I.D. NOTCHES. THEN REFER TO THE CHART TO SEE WHICH GASKETS ARE COMPATIBLE WITH THE MAIN CONTROLS AND SEPARATOR PLATES BEING USED. CAUTION MIXING COMPONENTS OTHER THAN THOSE LISTED MAY CAUSE SHIFT CONCERNS AND/OR DAMAGE TO THE TRANSMISSION. REFER TO THE PARTS CATALOG FOR PROPER USAGE BY MODEL AND YEAR. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-9-21 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 504000, 590000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 6468 Valve Body: Specifications TORQUE SPECIFICATIONS Main Control Valve Body ........................................................................................................................................................ 9-11 Nm (80-98 inch lbs.) Main Control Valve Body Cover Plate ..................................................................................................................................... 9-11 Nm (80-98 inch lbs.) Main Control Valve Body Separator Plate ............................................................................................................................... 9-11 Nm (80-98 inch lbs.) Valve Body Reinforcement Plates ............................................................................................................................................ 9-11 Nm (80-98 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 6469 Valve Body: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 6470 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 6471 Valve Body: Testing and Inspection 1. Thoroughly clean all parts, except the non-metallic check balls, in clean solvent and blow dry them with moisture-free compressed air. 2. Inspect all valve and plunger bores for scores. Check all fluid passages for obstructions. Inspect all mating surfaces for burrs and scores. If damaged, replace the main control valve body. 3. Inspect all springs for distortion. When dry, check all valves and plungers for free movement in their respective bores. 4. Roll the valves on a flat surface to check for bent condition. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation Valve Body: Service and Repair Removal and Installation REMOVAL 1. Disconnect the battery. 2. Raise and support the vehicle. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning OFF the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. 3. Drain the transmission fluid. Remove the transmission fluid pan, filter and seal. 4. Disconnect the solenoid and sensor electrical connectors. (1) Transmission Fluid Temperature (TFT) sensor. (2) Shift solenoids SS1 and SS2. (3) Torque Converter Clutch (TCC) solenoid. (4) Electronic Pressure Control (EPC) solenoid. CAUTION: Do not pull on the wires. This can damage the wires or the connector and can result in transmission solenoid or sensor failure. Carefully pry up on the locking tab and disconnect the connector. 5. Remove the manual valve detent spring. (1) Remove the bolt. (2) Remove the manual valve detent spring. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 6474 6. Remove the valve body-to-case bolts. 7. Remove the main control valve body. INSTALLATION 1. Position the main control valve body gasket and main control valve body using the two alignment bolts as a guide. NOTE: Make sure the manual valve detent lever assembly drive pin engages the manual valve in the proper location prior to installing the bolts. 2. Loosely install the 11 long main control valve body bolts. NOTE: The main control valve body bolts will be tightened in later steps. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 6475 3. Loosely install the 12 short main control valve body bolts. NOTE: The main control valve body bolts will be tightened in later steps. 4. Install the manual valve detent spring. (1) Position the manual valve detent spring. (2) Install the bolt. 5. Tighten the main control valve body bolts in the sequence shown. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 6476 6. Connect the solenoid and sensor electrical connectors. (1) Transmission fluid temperature (TFT) sensor. (2) Shift solenoids. (3) Torque converter control (TCC) solenoid. (4) Electronic pressure control (EPC) solenoid. 7. Replace the fluid filter and seal as required. CAUTION: If replacing the filter, and the seal remains in the main control bore, carefully use a small screwdriver to remove the seal. Use care not to damage the main control bore. NOTE: If the transmission is being repaired for a contamination-related failure, use a new filter and seal. The filter may be reused if no excessive contamination is present. 8. Position the pan magnet into the transmission fluid pan. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 6477 9. Install the transmission fluid pan. (1) Position the transmission pan gasket. (2) Position the transmission fluid pan. NOTE: The transmission fluid pan gasket is reusable. Clean and inspect for damage; if not damaged, reuse the gasket. 10. Install the transmission fluid pan bolts. 11. Remove the supports and lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. 12. Reconnect the battery ground cable. NOTE:When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. 13. Fill the transmission with fluid and check for proper operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 6478 Valve Body: Service and Repair Disassembly and Assembly Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 6479 DISASSEMBLY 1. Remove the torque converter clutch solenoid (TCC solenoid) and the shift solenoid (1) Remove the bolt. (2) Remove the torque converter clutch solenoid. (3) Remove the shift solenoid. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 6480 2. Remove the three reinforcement plates. (1) Remove the ten main control valve body separator plate bolts. (2) Remove the three reinforcement plates. 3. Remove the separator plate and discard the gaskets. 4. Remove the eight coasting booster valve shuttle balls. NOTE: Note the location of the eight coasting booster valve shuttle balls for assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 6481 5. Remove the converter drain back valve and solenoid pressure supply screen. 6. Remove the main control valve body cover plate. (1) Remove the thirteen bolts. (2) Remove the valve body cover plate and gasket. ASSEMBLY 1. Install the valve body cover plate. (1) Position the valve body cover plate gasket and cover plate. (2) Install the two guide pin bolts. (3) Install the valve body cover plate bolts. NOTE: Before beginning assembly, perform/inspect the following: - When building up subassemblies and assembling the transmission, ALWAYS use new gaskets and seals. - All fasteners must be tightened to the torque specification indicated. - When building up subassemblies, each component part should be lubricated with clean transmission fluid. It is also good practice to lubricate the subassemblies as they are installed in the case. - Needle bearings, thrust washers and seals should be lightly coated with petroleum jelly during subassembly buildup or transmission assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 6482 - Many components and surfaces in the transmission are precision machined. Careful handling during disassembly, cleaning, inspection and assembly can prevent unnecessary damage to machined surfaces. 2. Tighten the valve body cover plate bolts. 3. Install the eight coasting booster valve shuttle balls. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 6483 4. Install the converter drain back valve and solenoid pressure supply screen. 5. Install the separator plate and gaskets. 6. Install the three reinforcement plates. (1) Position the three reinforcement plates. (2) Install the ten bolts. 7. Install the shift solenoid. (1) Position the shift solenoid. (2) Position the TCC solenoid. (3) Install the bolt. NOTE: Inspect the shift solenoid O-rings and TCC solenoid O-rings for damage. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Side Gears > Component Information > Technical Service Bulletins > Customer Interest for Carrier Side Gears: > 99-14-3 > Jul > 99 > Front Differential - Moaning Noise In 2WD Mode Carrier Side Gears: Customer Interest Front Differential - Moaning Noise In 2WD Mode Article No. 99-14-3 07/12/99 ^ NOISE - "MOANING" FROM FRONT DIFFERENTIAL WHILE IN 2-WHEEL DRIVE - VEHICLES BUILT THROUGH 4/15/1999 ^ AXLE - "MOANING" NOISE FROM FRONT DIFFERENTIAL WHILE IN 2-WHEEL DRIVE VEHICLES BUILT THROUGH 4/15/1999 FORD: 1997-1999 EXPEDITION, F-150, F-250 LD LINCOLN: 1998-1999 NAVIGATOR ISSUE Some 4X4 vehicles built with center disconnect front axles may exhibit a "moaning" noise from the front differential while operating in 4X2 mode. The noise goes away when operating in 4X4 mode. This may be caused by the front differential side gears. ACTION Replace the front differential side gears with revised gears and replace the front differential pinion gears with revised gears. Refer to the following text for details. For vehicles that exhibit a front differential moan in 4X2 mode that goes away in 4X4 mode, replace both front axle side gears and both front axle pinion gears. Replace any worn or damaged pinion thrust washers and side gear washers. Refer to Section 205-03 of the appropriate model/year Workshop Manual for removal and installation procedures. PART NUMBER PART NAME XL3Z-4236-M Side Gears (2 Per Box) XL3Z-4215-M Pinion Gears (2 Per Box) DOAZ-4230-B Pinion Thrust washer C90Z-4228-B Side Gear washer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991403A Replace Axle Side Gears 1.4 Hrs. And Pinion Gears DEALER CODING CONDITION BASIC PART NO. CODE 4235 42 OASIS CODES: 509000, 597997, 702100 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Side Gears > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Carrier Side Gears: > 99-14-3 > Jul > 99 > Front Differential - Moaning Noise In 2WD Mode Carrier Side Gears: All Technical Service Bulletins Front Differential - Moaning Noise In 2WD Mode Article No. 99-14-3 07/12/99 ^ NOISE - "MOANING" FROM FRONT DIFFERENTIAL WHILE IN 2-WHEEL DRIVE - VEHICLES BUILT THROUGH 4/15/1999 ^ AXLE - "MOANING" NOISE FROM FRONT DIFFERENTIAL WHILE IN 2-WHEEL DRIVE VEHICLES BUILT THROUGH 4/15/1999 FORD: 1997-1999 EXPEDITION, F-150, F-250 LD LINCOLN: 1998-1999 NAVIGATOR ISSUE Some 4X4 vehicles built with center disconnect front axles may exhibit a "moaning" noise from the front differential while operating in 4X2 mode. The noise goes away when operating in 4X4 mode. This may be caused by the front differential side gears. ACTION Replace the front differential side gears with revised gears and replace the front differential pinion gears with revised gears. Refer to the following text for details. For vehicles that exhibit a front differential moan in 4X2 mode that goes away in 4X4 mode, replace both front axle side gears and both front axle pinion gears. Replace any worn or damaged pinion thrust washers and side gear washers. Refer to Section 205-03 of the appropriate model/year Workshop Manual for removal and installation procedures. PART NUMBER PART NAME XL3Z-4236-M Side Gears (2 Per Box) XL3Z-4215-M Pinion Gears (2 Per Box) DOAZ-4230-B Pinion Thrust washer C90Z-4228-B Side Gear washer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991403A Replace Axle Side Gears 1.4 Hrs. And Pinion Gears DEALER CODING CONDITION BASIC PART NO. CODE 4235 42 OASIS CODES: 509000, 597997, 702100 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Customer Interest: > 97-10-10 > May > 97 > Front Axle Tube Vent - Lubricant Leak Differential Case: Customer Interest Front Axle Tube Vent - Lubricant Leak Article No. 97-10-10 05/12/97 AXLE - FRONT - LUBRICANT LEAKING FROM FRONT AXLE TUBE VENT HOSE LIGHT TRUCK: 1997 EXPEDITION, F-150, F-250 LD This TSB article is being republished in its entirety to correct the Front Axle Vent part number. ISSUE: Axle lubricant may leak from the front axle tube vent hose on some vehicles. The vent hose is located close to the axle shaft, and as axle temperatures rise, the lubricant may be forced out through the vent hose. ACTION Install new Front Axle Tube Assembly with relocated vent port. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Install new Front Axle Tube Assembly (F75Z-4K206-AA) with revised port location (Figure 1). Refer to the 1997 Expedition Workshop Manual, Volume 1, Page 205-03-40, for front axle tube assembly removal and assembly procedures. NOTE: IF THE NEW TUBE ASSEMBLY IS NOT EQUIPPED WITH A VENT (SOME WERE SHIPPED WITHOUT VENTS), INSTALL NEW VENT (F65Z-4022-AA) AND TIGHTEN TO 18-26 N-m (13-19 LB-FT). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Customer Interest: > 97-10-10 > May > 97 > Front Axle Tube Vent - Lubricant Leak > Page 6507 2. Cut a 95 mm (3.75") length of Hose (F75Z-4A058-AA) and attach to the axle tube assembly vent (Figure 2). NOTE: TWO (2) VENTS MAY BE REQUIRED TO COMPLETE THIS REPAIR: ONE FOR THE AXLE TUBE IF NOT EQUIPPED, AND THE OTHER TO BE USED AS A CONNECTOR BETWEEN THE NEWLY CUT HOSE AND EXISTING VENT HOSE. 3. Insert the threaded end of the second vent into the open end of the 95 mm (3.75") hose. 4. Connect the existing vent hose to the 95 mm (3.75") hose. 5. Check the axle tube for leaks after axle installation. PART NUMBER PART NAME F75Z-4K206-AA Front Axle Tube Assembly F65Z-4022-AA Vent F75Z-4A058-AA Hose OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-9-21 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971010A Replace Tube Assembly 2.0 Hrs. (Includes Time To Install Vent If Required) DEALER CODING CONDITION BASIC PART NO. CODE 4K206 12 OASIS CODES: 509000, 510000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 97-10-10 > May > 97 > Front Axle Tube Vent Lubricant Leak Differential Case: All Technical Service Bulletins Front Axle Tube Vent - Lubricant Leak Article No. 97-10-10 05/12/97 AXLE - FRONT - LUBRICANT LEAKING FROM FRONT AXLE TUBE VENT HOSE LIGHT TRUCK: 1997 EXPEDITION, F-150, F-250 LD This TSB article is being republished in its entirety to correct the Front Axle Vent part number. ISSUE: Axle lubricant may leak from the front axle tube vent hose on some vehicles. The vent hose is located close to the axle shaft, and as axle temperatures rise, the lubricant may be forced out through the vent hose. ACTION Install new Front Axle Tube Assembly with relocated vent port. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Install new Front Axle Tube Assembly (F75Z-4K206-AA) with revised port location (Figure 1). Refer to the 1997 Expedition Workshop Manual, Volume 1, Page 205-03-40, for front axle tube assembly removal and assembly procedures. NOTE: IF THE NEW TUBE ASSEMBLY IS NOT EQUIPPED WITH A VENT (SOME WERE SHIPPED WITHOUT VENTS), INSTALL NEW VENT (F65Z-4022-AA) AND TIGHTEN TO 18-26 N-m (13-19 LB-FT). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 97-10-10 > May > 97 > Front Axle Tube Vent Lubricant Leak > Page 6513 2. Cut a 95 mm (3.75") length of Hose (F75Z-4A058-AA) and attach to the axle tube assembly vent (Figure 2). NOTE: TWO (2) VENTS MAY BE REQUIRED TO COMPLETE THIS REPAIR: ONE FOR THE AXLE TUBE IF NOT EQUIPPED, AND THE OTHER TO BE USED AS A CONNECTOR BETWEEN THE NEWLY CUT HOSE AND EXISTING VENT HOSE. 3. Insert the threaded end of the second vent into the open end of the 95 mm (3.75") hose. 4. Connect the existing vent hose to the 95 mm (3.75") hose. 5. Check the axle tube for leaks after axle installation. PART NUMBER PART NAME F75Z-4K206-AA Front Axle Tube Assembly F65Z-4022-AA Vent F75Z-4A058-AA Hose OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-9-21 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971010A Replace Tube Assembly 2.0 Hrs. (Includes Time To Install Vent If Required) DEALER CODING CONDITION BASIC PART NO. CODE 4K206 12 OASIS CODES: 509000, 510000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Case: > 98-5-8 > Mar > 98 > MIL ON/DTC P0503/Erratic Speedometer/Shifting Output Shaft: All Technical Service Bulletins MIL ON/DTC P0503/Erratic Speedometer/Shifting Article No. 98-5-8 03/16/98 ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODE (DTC) P0503 STORED IN MEMORY - 4X4 VEHICLES ONLY ^ TRANSMISSION - SHIFT CONCERNS AND/OR ERRATIC SPEEDOMETER OPERATION MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - 4X4 VEHICLES ONLY LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR This TSB article is being republished in its entirety to correct the parts listed. ISSUE: The Malfunction Indicator Lamp (MIL) may illuminate and Diagnostic Trouble Code (DTC) P0503 may be stored in memory. There may also be transmission shift concerns and/or erratic speedometer operation. This may be caused by the speedometer drive gear being loose on the transfer case output shaft. ACTION: Replace the speedometer drive gear. The new gear has a tighter fit and should reduce the possibility of erratic signals. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal diagnostics as outlined in the 1997 or 1998 Powertrain Control/Emissions Diagnosis (PC/ED) On-Board Diagnostics II (OBDII) Service Manual. Service as required. 2. If no concerns were found or the concern is still present, replace the speedometer drive gear. 3. Remove the four (4) rear driveshaft flange bolts and remove the rear driveshaft. NOTE: TO MAINTAIN INITIAL DRIVESHAFT BALANCE, MARK THE REAR DRIVESHAFT YOKE AND AXLE FLANGE SO THEY CAN BE REASSEMBLED IN THEIR ORIGINAL POSITIONS. 4. Remove the six (6) extension housing bolts and remove the rear extension housing. 5. Remove the speedometer gear spacer then push the speedometer drive gear toward the transfer case and remove the steel ball. The speedometer drive gear can now be removed from the output shaft. 6. To install the revised Speedometer Drive Gear (F7TZ-17285-AA), reverse the removal procedure. NOTE: THE NEW SPEEDOMETER DRIVE GEAR WILL HAVE A SLIGHT INTERFERENCE FIT, HOWEVER IT WILL GO ON TO THE OUTPUT SHAFT BY HAND. DO NOT HEAT THE GEAR. 7. Before installing the extension housing, apply a small bead of sealant to the transfer case cover and extension housing mating surfaces. Use Ford Ultra Silicone Sealant (F7TZ-19554-AA or equivalent). 8. Top off transfer case with MERCON® (XT-2-QDX). PART NUMBER PART NAME F7IZ-19554-AA Ultra Silicone Sealant F7TZ-17285-AA Speedometer Drive Gear Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Case: > 98-5-8 > Mar > 98 > MIL ON/DTC P0503/Erratic Speedometer/Shifting > Page 6519 XT-2-QDX MERCON(R) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-3-17 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 980508A Replace Speedometer 0.8 Hr. Drive Gear DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 33 OASIS CODES: 204000, 204100, 204200, 206000, 501000, 501200, 502000, 508000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Case: > 98-5-8 > Mar > 98 > MIL ON/DTC P0503/Erratic Speedometer/Shifting > Page 6525 XT-2-QDX MERCON(R) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-3-17 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 980508A Replace Speedometer 0.8 Hr. Drive Gear DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 33 OASIS CODES: 204000, 204100, 204200, 206000, 501000, 501200, 502000, 508000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Testing and Inspection > Front Differential Case: Testing and Inspection Front 1. Remove the front axle assembly. 2. Remove the axle housing cover. (1) Remove the drain plug. (2) Drain the differential lubricant. (3) Remove the bolts. (4) Remove the axle housing cover. 3. Install Bench Mounted Holding Fixture. CAUTION: Fixture mounting bolts (A) must have a minimum thread engagement in carrier. 4. Install Dial Indicator With Bracketry. 5. Check the ring gear runout. (1) Rotate the differential. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Testing and Inspection > Front > Page 6528 (2) Check and record the reading. 6. Refer to specifications to compare actual ring gear runout to verify it is within specifications. NOTE: If the ring gear runout check exceeds specification, the cause may be a warped ring gear, a damaged differential case or loss of differential bearing preload. To determine the cause of the excessive runout, proceed with the following stops. 7. Remove the pinion gear. 8. Remove the spreader. 9. Position the differential case with the differential bearing cups in the front axle housing. 10. Install the differential bearing shim on the left side. 11. Install the LH bearing cap. (1) Position the bearing cap. (2) Install the bolts finger tight. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Testing and Inspection > Front > Page 6529 12. Install progressively larger differential bearing shims on the RH side until the largest differential bearing shim can be assembled with a slight drag feel. 13. Tighten the bearing cap bolts. (1) Install the RH bearing cap and bolts. (2) Tighten the four bearing cap bolts. 14. Rotate the assembly to ensure free rotation. 15. Install Dial Indicator with Bracketry. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Testing and Inspection > Front > Page 6530 16. Check the ring gear runout. (1) Rotate the differential. (2) Check and record the reading. 17. If the runout is within specification, the original out-of-specification runout was caused by insufficient bearing preload. If the runout exceeds the specification, go to Step 18. 18. Remove the bearing caps. (1) Remove the bolts. (2) Remove the bearing caps. 19. Remove the differential case from the housing. 20. Remove the differential ring gear. (1) Remove the ten differential ring gear bolts. (2) Use a drift that will bottom out in the ring gear bolt holes to separate the (A) differential ring gear from the (B) differential case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Testing and Inspection > Front > Page 6531 21. Install the differential case in the housing without the ring gear. (1) Position the differential case. (2) Install the bearing caps. (3) Install the bearing cap bolts. 22. Position Dial Indicator With Bracketry. (1) Rotate the differential case to ensure the differential bearings are properly seated. (2) Position Dial Indicator With Bracketry. 23. Measure the differential case runout without the ring gear. (1) Rotate the differential case. (2) Check and note the differential case runout. 24. Remove the bearing caps. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Testing and Inspection > Front > Page 6532 (1) Remove the bearing cap bolts. (2) Remove the bearing caps. 25. Remove the differential case from the housing. NOTE: If runout is within specification, install a new ring gear and pinion. If runout exceeds specification, the ring gear is true and the concern is due to either a damaged differential case or differential bearings. Inspect the differential bearings. If the differential bearings are not damaged, replace both the differential case and the differential bearings. 26. Assemble Pinion and Carrier Bearing Puller. 27. Position Pinion and Carrier Bearing Puller. 28. Use Pinion and Carrier Bearing Puller to remove the differential bearing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Testing and Inspection > Front > Page 6533 - Repeat the procedure for the other side. 29. Install the new differential bearings. (1) Position the appropriate differential bearing (RH or LH). (2) Use the appropriate press to install the differential bearing. Repeat the procedure for the other differential bearing. NOTE: Press against the differential bearing inner cone only. 30. Install the differential case in the housing without the ring gear. (1) Position the differential case. (2) Install the bearing caps. (3) Install the bearing cap bolts. 31. Position the Dial Indicator With Bracketry. (1) Rotate the differential case to ensure differential bearings are properly seated. (2) Position the Dial Indicator With Bracketry. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Testing and Inspection > Front > Page 6534 32. Recheck runout with the new differential case and differential bearings. (1) Rotate the differential case. (2) Recheck and note the differential case runout. NOTE: If runout is now within specification, use new differential bearings for assembly. If runout is still excessive, differential case is damaged and should be replaced. 33. Remove the bearing caps bolts. 34. Remove the differential case from the housing. (1) Remove the bearing caps. (2) Remove the differential case. 35. Install the pinion gear and the ring gear. 36. Install the Front Drive Axle assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Testing and Inspection > Front > Page 6535 Differential Case: Testing and Inspection Rear Bench Torque Test - 8.8 Inch Axle 1. Mount the differential case and Traction-Lok13 Torque Tool in a vise. 2. Check the torque required to rotate one differential side gear. - The initial break-away torque using the original clutch plates should be within specification. The rotating torque required to keep the differential side gear turning with new clutch plates may vary. Bench Torque Test - 9.75 Inch Axle 1. Check the torque required to rotate one differential side gear. - Mount the differential case and Traction-Lok Torque Tool Set in a vise. - The initial break-away torque, if original clutch plates are used, must be within specification. The rotating torque required to keep the differential side gear turning with new clutch plates can vary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front Differential Case: Service and Repair Front Replacement REMOVAL 1. Remove the cluster gear clutch thrust washer. 2. Remove the front axle cluster gear. 3. Remove the axle shaft. (1) Reposition the carrier assembly in the Bench Mounted Holding Fixture. (2) Remove the axle shaft snap ring. (3) Remove the axle shaft. 4. Install the Housing Spreader Adapter (A) (left) and (B) (right). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6538 CAUTION: Housing spreader adapter bolts have a minimum thread engagement. 5. Position Carrier Housing Spreader on the spreader adapters. 6. If necessary, adjust Carrier Housing Spreader to provide clearance for the shift lever. 7. Install (A) Dial Indicator on (B) Dial Indicator Bracketry and position (C) Clutch Housing Adapter with the tip in the (D) spreader adapter hole. 8. Spread the front axle housing. (1) Adjust Dial Indicator to zero. (2) Tighten the housing spreader screw until the front axle housing is spread to specification. (3) Remove Dial Indicator. CAUTION: Overspreading may cause damage to the front axle housing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6539 9. Remove the differential bearing caps. (1) Remove the bolts. (2) Remove the differential bearing caps and mark or tag them right or left. NOTE: Differential bearing caps must be installed in the original place and position. See reference arrows on differential bearing caps. 10. Remove the differential case from the front axle housing. (1) Position the wood blocks. (2) Use two pry bars; push down on the pry bars. (3) Remove the differential case. CAUTION: Wood blocks must be used to avoid front axle housing damage. 11. Remove differential bearing shims. NOTE: Differential bearing shims must be installed in the original place and position. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6540 INSTALLATION 1. Position the differential bearing shims. (1) Apply a light coating of Premium Long Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B to one side of the differential bearing shims to help hold them in place. (2) Position the differential bearing shims. CAUTION: Never attempt to drive differential bearing shim in place. The front axle housing machined surfaces may be permanently damaged. 2. Position the differential case assembly. (1) Position the differential bearing cups on the differential bearings. (2) Lower the differential case assembly in place between the differential bearing shims. NOTE: Push the differential case down to fully seat the differential bearing cups in the front axle housing. 3. Install the bearing caps in their original positions and tighten with the housing still spread. (1) Position the bearing caps. (2) Install the bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6541 4. Remove the Differential Housing Spreader and reposition the Dial Indicator Bracketry. 5. Measure the ring gear backlash. (1) Mount the (A) dial indicator on the (B) indicator base. (2) Position the indicator needle and zero the indicator. (3) Turn the (C) ring gear without turning the (D) pinion gear and record the measurement. NOTE: Measure the ring gear backlash at four places to obtain consistent reading. - If backlash is not within specification, correct by increasing thickness of one differential bearing shim and decreasing thickness on the other differential bearing shim by the same amount. 6. To increase the backlash, install (A) thicker differential bearing shim and (B) thinner differential bearing shim as shown. 7. To decrease backlash, install (A) thicker differential bearing shim and (B) thinner differential bearing shim as shown. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6542 8. Examine the axle shaft seal and bearing surface for damage. If necessary, polish the bearing surface with fine crocus cloth. 9. Insert the axle shaft and engage it with the side gear. 10. Push in on the (A) axle shaft and install a new (B) snap ring. NOTE: Do not reuse old snap ring. 11. Insert the (A) clutch gear through the (B) selector gear and (C) engage the splines. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6543 12. Use Premium Long Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B to coat the thrust washer and position it on the clutch gear. 13. Install front axle tube. Disassembly and Assembly DISASSEMBLY 1. Remove the differential case from the front drive axle assembly. 2. Remove the differential ring gear. (1) Remove the ten differential ring gear bolts. (2) Use a drift that will bottom out in the ring gear bolt holes to separate the (A) differential ring gear from the (B) differential case. 3. Remove the differential pinion shaft lock bolt from the differential case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6544 4. Remove the differential pinion shaft. 5. Remove the differential pinion thrust washers. (1) Rotate the differential pinion gears to the differential case window and remove. (2) Remove the differential pinion thrust washers. 6. Remove the (A) differential side gears and the (B) differential side gear thrust washers. ASSEMBLY 1. Use Motorcraft SAE 75W90 4x4 Axle Lubricant XY-75W90-QL meeting Ford specification WSP-M2C201-A to lubricate the differential side gear thrust washers and the differential side gear journals. Position the (A) differential side gear thrust washers on the (B) differential side gears. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6545 2. Position the differential side gears. 3. Use Motorcraft SAE 75W90 4x4 Axle Lubricant XY-75W90-QL meeting Ford specification WSP-M2C201-A to lubricate the differential pinion thrust washers and the differential pinion gears and assemble. 4. Engage the differential pinion gears opposite the differential side gears. 5. Rotate the differential pinion gears to align the differential pinion shaft bore. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6546 6. Insert the differential pinion shaft. 7. Install new differential pinion shaft lock bolt. NOTE: If a new pinion shaft lock bolt is unavailable, coat the threads with Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specifications WSK-M2G315-A5 and ESE-M4G204-A2 prior to installation. 8. Install the ring gear. (1) Position and then start three (C) ring gear bolts to align the holes in the (A) ring gear and the (B) differential case. (2) Use an appropriate press to install the ring gear. 9. Install the remaining ring gear bolts. 10. Install the differential case into the front drive axle housing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6547 Differential Case: Service and Repair Rear 8.8-Inch Ring Gear DISASSEMBLY 1. Remove the 10 ring gear bolts. 2. Use a drift that will bottom out in the ring gear bolt holes to separate the differential ring gear from the differential case. 3. Remove the speed sensor ring. NOTE: The speed sensor ring cannot be reused once removed. 4. Use 2-Jaw Puller and Step Plate to remove the differential bearing(s). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6548 5. Remove the pinion shaft lock bolt and the differential pinion shaft. 6. Rotate and remove the differential pinion gears and the differential pinion thrust washers. 7. Remove the differential side gears and the differential side gear thrust washers. ASSEMBLY 1. Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A to lubricate the differential side gear thrust washers and the differential side gear journals. Position the differential side gear thrust washers on the differential side gears. 2. Position the differential side gears. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6549 3. Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19850-B or equivalent meeting Ford specification WSL-M2C192-A to lubricate the differential pinion thrust washers and the differential pinion gears and assemble. 4. Engage the differential pinion gears opposite the differential side gears. 5. Rotate the differential pinion gears to align the differential pinion shaft bore. 6. Insert the differential pinion shaft. 7. Install the differential pinion shaft lock bolt. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6550 NOTE: If a new pinion shaft lock bolt is unavailable, coat the threads with Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G315-A5 and ESE-M4G204-A2 prior to installation. 8. Install the anti-lock speed sensor ring by aligning the tab on the anti-lock speed sensor ring with the slot on the differential case. 9. Press the new (A) anti-lock speed sensor ring and the (B) ring gear on the differential case. NOTE: Thread two bolts into the ring gear while pressing to align the bolt holes. 10. Use Differential Side Bearing Replacer to install the differential bearings on the differential case. 11. Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to ring gear bolts and install the 10 ring gear bolts. 9.75-Inch Ring Gear Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6551 DISASSEMBLY 1. Remove the 12 ring gear bolts. 2. Use a drift that will bottom out in the ring gear bolt holes to separate the differential ring gear from the differential case. 3. Remove the speed sensor ring. NOTE: The speed sensor ring cannot be reused once removed. 4. Use 2-Jaw Puller and Step Plate to remove the differential bearing(s). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6552 5. Remove the pinion shaft lock bolt and the differential pinion shaft. 6. Rotate and remove the differential pinion gears and the differential pinion thrust washers. 7. Remove the differential side gears and the differential side gear thrust washers. ASSEMBLY 1. Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A to lubricate the differential side gear thrust washers and the differential side gear journals. Position the differential side gear thrust washers on the differential side gears. 2. Position the differential side gears. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6553 3. Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19850-B or equivalent meeting Ford specification WSL-M2C192-A to lubricate the differential pinion thrust washers and the differential pinion gears and assemble. 4. Engage the differential pinion gears opposite the differential side gears. 5. Rotate the differential pinion gears to align the differential pinion shaft bore. 6. Insert the differential pinion shaft. 7. Install the differential pinion shaft lock bolt. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6554 NOTE: If a new pinion shaft lock bolt is unavailable, coat the threads with Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G315-A5 and ESE-M4G204-A2 prior to installation. 8. Install the anti-lock speed sensor ring by aligning the tab on the anti-lock speed sensor ring with the slot on the differential case. 9. Press the new (A) anti-lock speed sensor ring and the (B) ring gear on the differential case. NOTE: Thread two bolts into the ring gear while pressing to align the bolt holes. 10. Use Differential Side Bearing Replacer to install the differential bearings on the differential case. 11. Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to ring gear bolts and install the 12 ring gear bolts. Traction-LOK Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6555 DISASSEMBLY 1. Remove the 10 ring gear bolts. 2. Remove the differential ring gear. (1) Insert the drift into the bolt hole. (2) Tapping from side to side, remove the differential ring gear. NOTE: Use a drift that will bottom out in the ring gear bolt holes to separate the differential ring gear from the differential case. 3. Remove the speed sensor ring. NOTE: The speed sensor ring cannot be reused once removed. 4. Use 2-Jaw Puller and Step Plate to remove the differential bearings. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6556 5. Remove the differential pinion shaft. (1) Remove the differential pinion shaft lock bolt. (2) Remove the differential pinion shaft. 6. Remove the differential clutch spring. WARNING: DUE TO THE SPRING TENSION, CARE MUST BE USED WHEN REMOVING THE DIFFERENTIAL CLUTCH SPRING. 7. Use Gear Rotator to rotate the pinion gears until they can be removed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6557 8. Remove the differential gears. (1) Remove the differential pinion gears. (2) Remove the differential side gears and clutch packs. (3) Remove the thrust washers. NOTE: The differential side gears and clutch packs must be tagged LEFT and RIGHT for proper assembly. ASSEMBLY NOTE: Clutch Pack Preload adjustment is necessary for the assembly of the differential case. See: Differential Clutch/Adjustments/Clutch Pack Preload - 8.8 Inch Axle 1. Install the differential side gears and clutch packs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6558 2. Install the differential pinion gears with thrust washers. 3. Install the differential clutch spring. 4. Install the differential pinion shaft. (1) Position the differential pinion shaft. (2) Install the differential pinion shaft lock bolt. 5. Use Differential Side Bearing Replacer to install the differential bearings on the differential case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6559 6. Install the anti-lock speed sensor ring by aligning the tab on the anti-lock speed sensor ring with the slot on the differential case. 7. Start two of the ring gear bolts to make sure the alignment is correct. 8. Press the new (A) anti-lock speed sensor ring and the (B) ring gear on the differential case. 9. Install the ring gear bolts. - Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to ring gear bolts. Disassembly 1. Remove the ring gear bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6560 2. Use a drift that will bottom out in the ring gear bolt holes to separate the differential ring gear from the differential case. 3. Remove the speed sensor ring. NOTE: The sensor ring cannot be reused once it has been removed. 4. Remove the differential pinion shaft. (1) Remove the differential pinion shaft lock bolt. (2) Remove the differential pinion shaft. 5. Install Traction-Lok Torque Tool in a suitable vise. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6561 6. Position the differential case on Traction-Lok Tool with the ring gear side facing up. 7. Install Step Plate. - Apply a small amount of Premium Long-Life Grease XG-1-C or XG-1-K or equivalent meeting Ford specification ESA-M1C75-B. 8. Install Limited Slip Differential Tool in the differential case. 9. Tighten Limited Slip Differential Tool to force the differential side gears away from the differential pinion gears. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6562 10. Use Limited Slip Differential Rotating Tool to turn the differential case to walk the differential pinion gears out to the differential case windows and remove the differential pinion gears with thrust washers. WARNING: KEEP FINGERS/HANDS AWAY FROM PINION GEARS WHEN ROTATING DIFFERENTIAL CASE WITH DIFFERENTIAL ROTATING TOOL. 11. Remove Limited Slip Differential Tool. 12. Remove the left side differential side gear and clutch pack. NOTE: The differential side gears and clutch packs must be tagged LEFT and RIGHT for proper assembly. 13. Remove Step Plate. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6563 14. Remove the right side differential side gear and clutch pack. NOTE: The differential side gears and clutch packs must be tagged LEFT and RIGHT for proper assembly. 15. Use 2-Jaw Puller for differential case bearing along with Step Plate to remove the differential case bearing. Assembly NOTE: Clutch pack preload adjustment is necessary for the assembly of the differential case. See: Differential Clutch/Adjustments/Clutch Pack Preload - 9.75 Inch Axle 1. Use Differential Bearing Cone Replacer to install the new differential case bearings. 2. Position the right side differential side gear and clutch pack. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6564 3. Position Step Plate. 4. Position the left side differential side gear and clutch pack. 5. Install Limited Slip Differential Tool in the differential case and tighten two turns after it contacts Step Plate. - Apply a small amount of Premium Long-Life Grease XG-1-C or XG-1-K or equivalent meeting Ford specification ESA-M1C75-B. 6. Prelubricate the differential pinion gears and both sides of the thrust washers with Motorcraft Synthetic Rear Axle Lubricant F1IZ-19580-B or equivalent meeting Ford Specification WSL-M2C192-A. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6565 7. Insert the differential pinion gears and thrust washers into mesh with the side gears 180 degrees apart and use Limited Slip Differential Rotating Tool to turn the differential case, walking the differential pinion gears into position. WARNING: KEEP FINGERS/HANDS AWAY FROM PINION GEARS WHEN ROTATING DIFFERENTIAL CASE WITH DIFFERENTIAL ROTATING TOOL. NOTE: It may be necessary to tighten or loosen Limited Slip Differential Tool to allow the differential pinion gears and differential side gears to rotate. 8. Remove Limited Slip Differential Tool from the differential case. 9. Remove Step Plate. 10. Remove the differential case from the vise. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 6566 11. Install the differential pinion shaft. (1) Position the differential pinion shaft. (2) Install the differential pinion shaft lock bolt. 12. Press the new (A) anti-lock speed sensor ring and the (B) ring gear onto the differential case. NOTE: Thread two bolts into the ring gear while pressing to align the bolt holes. 13. Install the remaining ring gear bolts. - Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to the ring gear bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > Customer Interest: > 98-11-7 > Jun > 98 > Rear Axle - Chattering On Turns Or Cornering Differential Clutch: Customer Interest Rear Axle - Chattering On Turns Or Cornering Article No. 98-11-7 06/08/98 ^ NOISE - "CHATTERING" NOISE FROM REAR AXLE HEARD ON TURNS OR WHEN CORNERING - VEHICLES WITH LIMITED SLIP AXLE ^ AXLE - LIMITED SLIP - REAR AXLE "CHATTERING" NOISE ON TURNS OR WHEN CORNERING LIGHT TRUCK: 1997-98 E-150, EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR ISSUE A "chattering" noise from the rear axle may be heard when turning or cornering. This may be due to differentials containing clutch packs that have been gauged too tightly. ACTION Install new Traction-Lok Clutch Pack Kit. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Confirm axle chatter with road test. 2. Once axle chatter has been confirmed, remove and discard old clutch packs, shims and Belleville springs. Refer to the appropriate Workshop Manual for details. NOTE SUBTRACT 0.25 mm (0.010") FROM FEELER GAUGE READING TAKEN DURING SHIM SELECTION USING SERVICE TOOLS AND PROCEDURES INDICATED ON INSTRUCTION SHEETS PACKAGED WITH KITS. 3. Install Clutch Pack Kit F75Z-4947-AA for 9.75-inch ring gear Tracktion-Lok axles and Kit F75Z-4947-AB for 10.25-inch ring gear Traction-Lok axles. For ring gear size and differential type, see embossed metal tag attached to rear axle cover. Refer to the appropriate Workshop Manual for details. PART NUMBER PART NAME F75Z-4947-AA Clutch Pack Kit (9.75" Ring Gear) F75Z-4947-AB Clutch Pack Kit (10.25" Ring Gear) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 981107A Install Clutch Pack (Drum 2.2 Hrs. Brake Applications) 981107B Install Clutch Pack (Disc 2.4 Hrs. Brake Applications Without 981107C Install Clutch Pack (Disc 2.5 Hrs. Brake Applications With Air Suspension) DEALER CODING CONDITION BASIC PART NO. CODE 4026 56 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > Customer Interest: > 98-11-7 > Jun > 98 > Rear Axle - Chattering On Turns Or Cornering > Page 6575 OASIS CODES: 509000, 510000, 597997, 702000, 702200 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-11-7 > Jun > 98 > Rear Axle - Chattering On Turns Or Cornering Differential Clutch: All Technical Service Bulletins Rear Axle - Chattering On Turns Or Cornering Article No. 98-11-7 06/08/98 ^ NOISE - "CHATTERING" NOISE FROM REAR AXLE HEARD ON TURNS OR WHEN CORNERING - VEHICLES WITH LIMITED SLIP AXLE ^ AXLE - LIMITED SLIP - REAR AXLE "CHATTERING" NOISE ON TURNS OR WHEN CORNERING LIGHT TRUCK: 1997-98 E-150, EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR ISSUE A "chattering" noise from the rear axle may be heard when turning or cornering. This may be due to differentials containing clutch packs that have been gauged too tightly. ACTION Install new Traction-Lok Clutch Pack Kit. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Confirm axle chatter with road test. 2. Once axle chatter has been confirmed, remove and discard old clutch packs, shims and Belleville springs. Refer to the appropriate Workshop Manual for details. NOTE SUBTRACT 0.25 mm (0.010") FROM FEELER GAUGE READING TAKEN DURING SHIM SELECTION USING SERVICE TOOLS AND PROCEDURES INDICATED ON INSTRUCTION SHEETS PACKAGED WITH KITS. 3. Install Clutch Pack Kit F75Z-4947-AA for 9.75-inch ring gear Tracktion-Lok axles and Kit F75Z-4947-AB for 10.25-inch ring gear Traction-Lok axles. For ring gear size and differential type, see embossed metal tag attached to rear axle cover. Refer to the appropriate Workshop Manual for details. PART NUMBER PART NAME F75Z-4947-AA Clutch Pack Kit (9.75" Ring Gear) F75Z-4947-AB Clutch Pack Kit (10.25" Ring Gear) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 981107A Install Clutch Pack (Drum 2.2 Hrs. Brake Applications) 981107B Install Clutch Pack (Disc 2.4 Hrs. Brake Applications Without 981107C Install Clutch Pack (Disc 2.5 Hrs. Brake Applications With Air Suspension) DEALER CODING CONDITION BASIC PART NO. CODE 4026 56 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-11-7 > Jun > 98 > Rear Axle - Chattering On Turns Or Cornering > Page 6581 OASIS CODES: 509000, 510000, 597997, 702000, 702200 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Clutch: > 06-21-19 > Oct > 06 > A/C Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Clutch: > 06-21-19 > Oct > 06 > A/C Heater Core Electrolysis/Leakage > Page 6587 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Clutch: > 06-21-19 > Oct > 06 > A/C Heater Core Electrolysis/Leakage > Page 6588 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Clutch: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes - Service Tip. Heater Hose: All Technical Service Bulletins Rear Air Conditioning Lines/Tubes - Service Tip. Article No. 97-14-20 07/07/97 ^ AIR CONDITIONING - REAR AUXILIARY UNDERBODY A/C LINES AND TUBES - SERVICE TIP ^ COOLING SYSTEM - REAR AUXILIARY UNDERBODY HEATER LINES AND TUBES SERVICE TIP LIGHT TRUCK: 1997 EXPEDITION ISSUE: Additional information has been released by Ford Motor Company regarding the servicing of the underbody tubes and hoses for the rear auxiliary A/C and heater systems. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Clutch: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes - Service Tip. > Page 6593 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Clutch: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes - Service Tip. > Page 6594 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Clutch: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes - Service Tip. > Page 6595 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Clutch: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes - Service Tip. > Page 6596 ACTION: When servicing the underbody tubes and hoses for the rear auxiliary A/C and heater, refer to the following illustrations (Figures 1-4) to determine correct part number and part locations. Refer to the 1997 Expedition Workshop Manual for all part removal and installation procedures. PART NUMBER PART NAME F75Z-18663-KA Front Heater Outlet Tube Kit F75Z-18696-KA Front Heater Inlet Tube Kit F75Z-18663-LA Rear Heater Outlet Tube Kit F75Z-18696-LA Hear Heater Inlet Tube Kit F75Z-19867-KA Rear A/C Suction Tube Kit F75Z-19835-JA Rear A/C Liquid Tube Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Clutch: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes - Service Tip. > Page 6597 OASIS CODES: 208100, 208200, 208999, 290000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Clutch: > 06-21-19 > Oct > 06 > A/C Heater Core Electrolysis/Leakage > Page 6603 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Clutch: > 06-21-19 > Oct > 06 > A/C Heater Core Electrolysis/Leakage > Page 6604 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Clutch: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes - Service Tip. > Page 6609 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Clutch: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes - Service Tip. > Page 6610 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Clutch: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes - Service Tip. > Page 6611 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Clutch: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes - Service Tip. > Page 6612 ACTION: When servicing the underbody tubes and hoses for the rear auxiliary A/C and heater, refer to the following illustrations (Figures 1-4) to determine correct part number and part locations. Refer to the 1997 Expedition Workshop Manual for all part removal and installation procedures. PART NUMBER PART NAME F75Z-18663-KA Front Heater Outlet Tube Kit F75Z-18696-KA Front Heater Inlet Tube Kit F75Z-18663-LA Rear Heater Outlet Tube Kit F75Z-18696-LA Hear Heater Inlet Tube Kit F75Z-19867-KA Rear A/C Suction Tube Kit F75Z-19835-JA Rear A/C Liquid Tube Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Clutch: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes - Service Tip. > Page 6613 OASIS CODES: 208100, 208200, 208999, 290000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Adjustments > Clutch Pack Preload - 8.8 Inch Axle Differential Clutch: Adjustments Clutch Pack Preload - 8.8 Inch Axle 1. Separate the clutch discs and friction plates for cleaning and inspection. CAUTION: When separating the clutch discs and clutch friction plates, note the sequence in which they are disassembled. They must be reassembled in the same sequence. 2. Clean and inspect the differential clutch packs for wear and replace parts as necessary. NOTE: Do not use acids or solvents when cleaning the differential clutch pack. Wipe components with a clean, lint-free cloth only. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Adjustments > Clutch Pack Preload - 8.8 Inch Axle > Page 6616 3. Assemble the (A) differential clutch packs (without the shims) on the (B) respective differential side gears. NOTE: Do not mix the differential clutch packs or shims from one side with the other. 4. Place the base portion of (A) Traction-Lok Clutch Gauge in a vise. Install the (B) differential clutch pack and differential side gear (without the shim) over the base. NOTE: Use the mandrel from Traction-Lok Clutch Gauge for the procedure. 5. Assemble a clutch pack onto Traction Poke Clutch Gauge. (1) Assemble the top half of Traction Coke Clutch Gauge on top of the clutch pack. (2) Tighten the nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Adjustments > Clutch Pack Preload - 8.8 Inch Axle > Page 6617 6. Use Feeler Gauge and select the thickest blade that will enter between the tool and the differential clutch pack. The reading will be the thickness of the new clutch shim. 7. Prelubricate each clutch disc and soak clutch friction plates for at least 15 minutes in Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Adjustments > Clutch Pack Preload - 8.8 Inch Axle > Page 6618 Differential Clutch: Adjustments Clutch Pack Preload - 9.75 Inch Axle 1. Separate the clutch discs and clutch friction plates for cleaning and inspection. CAUTION: When separating the clutch discs and clutch friction plates, note the sequence in which they are disassembled. They must be reassembled in the same sequence. 2. Clean and inspect the differential clutch packs for wear and replace parts as necessary. NOTE: Do not use acids or solvents when cleaning the differential clutch pack. Wipe components with a clean, lint-free cloth only. 3. Assemble the clutch packs. (1) Prelubricate the thrust face of the differential side gears with Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. (2) Assemble the clutch plates and clutch discs to the side gear splines in exactly the same sequence in which they were removed. NOTE: Do not mix the differential clutch packs or shims from one side with the other. 4. Clamp the bolt head of the Traction-Lok Clutch Gauge (Mandrel) in a vise. Install the differential clutch pack and the differential side gear (without the shim or the Belleville spring) on Traction-Lok Clutch Gauge (Mandrel). 5. Position Traction-Lok Clutch Gauge on top of the clutch pack. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Adjustments > Clutch Pack Preload - 8.8 Inch Axle > Page 6619 6. Install the Traction-Lok Clutch Gauge over the disc and clutch pack. 7. Install the nut. 8. Use Feeler Gauge and select the thickest blade that can be inserted between the tool and the differential clutch pack. The reading will be the thickness of the new clutch shim. 9. Prelubricate each clutch disc and soak clutch friction plates for at least 15 minutes in Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > 8.8 Inch Ring Gear Differential Cover: Service and Repair 8.8 Inch Ring Gear REMOVAL 1. Raise and support the vehicle. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. 2. Remove the axle housing cover. (1) Loosen the bolts and drain the lubricant. (2) Remove the bolts. (3) Remove the axle housing cover. INSTALLATION 1. Clean the gasket mating surface of the rear axle and the axle housing cover. CAUTION: Make sure the machined surfaces on both the axle housing and the axle housing cover are clean and free of oil before installing the new silicone sealant. The inside of the rear axle must be covered when cleaning the machined surface to prevent contamination. 2. Apply a new, continuous bead of sealant to the axle housing cover. - Use Silicone Rubber (Black) F4AZ-19562-B or equivalent meeting Ford specification WSE-M4G323-A1. 3. Install the axle housing cover. (1) Install the axle housing cover. (2) Install the bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6624 NOTE: The axle housing cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied. If possible, allow one hour before filling with lubricant to make sure silicone sealant has properly cured. 4. Fill the rear axle with Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A and install the filler plug. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6625 Differential Cover: Service and Repair 9.75 Inch Ring Gear REMOVAL 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Remove the axle housing cover. (1) Remove the bolts and drain the lubricant. (2) Remove the axle housing cover. INSTALLATION 1. Clean the gasket mating surface of the rear axle and the axle housing cover. CAUTION: Make sure the machined surfaces on both the axle housing and the axle housing cover are clean and free of oil before installing the new silicone sealant. The inside of the rear axle must be covered when cleaning the machined surface to prevent contamination. 2. Apply a new, continuous bead of sealant to the axle housing cover. - Use Silicone Rubber (Black) F4AZ-19562-B or equivalent meeting Ford specification WSE-M4G323-A1. 3. Install the axle housing cover. (1) Install the axle housing cover. (2) Install the bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6626 NOTE: The axle housing cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied. If possible, allow one hour before filling with lubricant to make sure silicone sealant has properly cured. 4. Fill the rear axle with Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A and install the filler plug. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair Differential Axle Housing: Service and Repair Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Page 6630 Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Page 6631 Special Tools 1. Remove the front drive axle assembly. 2. Remove the axle housing cover. 1 Remove the drain plug. 2 Drain the differential fluid. 3 Remove the bolts. 4 Remove the differential cover. 3. CAUTION: Fixture mounting bolts must have a minimum thread depth in the carrier. Install the front drive axle assembly in the Bench Mounted Holding Fixture. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Page 6632 4. Unseat the clutch shaft rod boot, and remove the snap ring. 5. Disconnect the front axle actuator motor assembly. 1 Fully extend the front axle actuator motor shaft. 2 Plug the vacuum ports. 3 Pull the front axle actuator motor assembly out. 4 Push the front axle actuator motor assembly away, disconnecting the lever from the slot in the actuator motor shaft. 6. Remove the front axle actuator motor assembly and boot. 1 Remove the boot. 2 Remove the front axle actuator motor assembly. 7. Remove the front axle housing tube assembly. - Reposition the front drive axle assembly in the Bench Mounted Holding Fixture. - Remove the bolts. - Remove the front axle housing tube assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Page 6633 8. Remove the cluster gear clutch thrust washer. 9. Remove the front axle cluster gear. 10. Remove the front axle shaft pilot bearing from the front axle cluster gear. 1 Position the front axle cluster gear in the vise. 2 Use Blind Hole Puller and Slide Hammer to remove the front axle shaft pilot bearing. 11. Lift the front axle shift lever and remove the selector gear. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Page 6634 12. NOTE: Clearance is provided in casting for roll pin removal. If necessary, remove the shift lever assembly and the shift fork assembly. Drive the manual shaft retaining pin through the shift fork. - Remove the shift lever assembly and the shift fork assembly. 13. Remove the axle shaft. 1 Reposition the carrier assembly in the Bench Mounted Holding Fixture. 2 Remove the axle shaft snap ring. 3 Remove the axle shaft 14. CAUTION: Housing spreader adapter bolts have a minimum thread engagement. Install the left and right Housing Spreader Adapter tools. 15. Position the Carrier Housing Spreader on the spreader adapters. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Page 6635 16. If necessary, adjust the Carrier Housing Spreader to provide clearance for the shift lever. 17. Install the Dial Indicator and Bracketry and position with the tip in the spreader adapter hole. 18. Spread the front axle housing. 1 Adjust the Dial Indicator to zero. 2 Tighten the housing spreader screw until the front axle housing is spread to specification. 3 Remove the Dial Indicator. 19. NOTE: Differential bearing caps must be installed in the original place and position. See reference arrows on differential bearing caps. Remove the differential bearing caps. 1 Remove the bolts. 2 Remove the differential bearing caps and mark or tag them right or left. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Page 6636 20. CAUTION: Wood blocks must be used to avoid front axle housing damage. Remove the differential case from the front axle housing. 1 Position the wood blocks. 2 Use two pry bars and push down on the pry bars. 3 Remove the differential case. 4 Remove Differential Housing Spreader. 21. Mark the front axle universal joint flange and index it to the pinion stem. 1 Reposition the front axle housing in the Bench Mounted Holding Fixture. 2 Mark the front axle universal joint flange and index it to the pinion stem. 22. Install the Companion Flange Holding Tool with bolts, and loosen the pinion nut. 23. With the pinion nut still engaged by a few threads, install the 2-Jaw Puller and remove the front axle universal joint flange. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Page 6637 24. Remove the pinion from the carrier housing. 1 Hold the pinion inside the carrier housing. 2 Use a soft face hammer and remove the pinion from the carrier housing. 25. CAUTION: Do not damage the front axle housing while removing the pinion seal. Remove the pinion seal and oil slinger. 26. Use the Puller Tool and the Slide Hammer to remove the inner bearing cup. 27. NOTE: A baffle to aid bearing lubrication is positioned behind the inner bearing cup. Normally this can be left in position if the inner bearing cup is removed. If necessary, remove the baffle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Page 6638 28. Remove the outer axle pinion bearing cup, tapping alternately on each side to prevent the outer axle pinion bearing cup from cocking. 29. Remove the differential pinion bearing. - Install the Pinion Bearing Cone Remover on the differential pinion bearing assembly. - Position the Pinion Bearing Cone Remover and the differential pinion bearing assembly in a press and press the bearing off. 30. NOTE: Measure the drive pinion bearing adjustment shim (which is found under the differential pinion bearing) with a micrometer and record the thickness (use this as a reference to compare the shim gauge reading prior to installing the differential pinion bearing). Remove the drive pinion bearing adjustment shim from the differential pinion gear. 31. Remove the differential ring gear. - Remove the ten differential ring gear bolts. - Use a drift punch to separate the differential ring gear from the differential case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Page 6639 32. Use the 2-Jaw Puller and the Step Plate to remove the differential bearings. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications With Dana 50 Axle Differential Fluid Capacity Capacity (Refill) ................................................................................................................................... .................................................................... 3.8 Pints With Dana 60 Axle Differential Fluid Capacity Capacity (Refill) ................................................................................................................................... .................................................................... 6.0 Pints Rear Differential Fluid Capacity With 8.8 & 9.75 Inch ring Gear ............................................................................................................ ................................................................... 5.5 Pints With 10.25 Inch ring Gear .................................................................................................................... .................................................................... 7.5 Pints Fill no higher than 1/4 to 9/16 inch below fill plug. 8.8 inch and 10.25 inch ring gear differentials have a removable cover. 9.25 inch does not. Limited slip type differentials include 4 oz of friction modifier C8AZ-19B956-A in capacity. To determine standard or limited slip type, check axle code on label on door lock pillar. Standard axles consist of two numbers. Limited slip codes consist of one letter and one number. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 6644 Fluid - Differential: Fluid Type Specifications Front Front Differential .................................................................................................................................. .......................................................... 75W-90 GL-5 Note: Part no. XY-75W90-QL meeting Ford Specification WSP-M2C201-A Rear Standard .............................................................................................................................................. .......................................... Synthetic 75W-140 GL-5 Limited Slip .......................................................................................................................................... ...................................... Synthetic 75W-140 GL-5+ Note: Part no. XY-75W140-QL Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Technical Service Bulletins > Customer Interest for Pinion Gear: > 99-14-3 > Jul > 99 > Front Differential Moaning Noise In 2WD Mode Pinion Gear: Customer Interest Front Differential - Moaning Noise In 2WD Mode Article No. 99-14-3 07/12/99 ^ NOISE - "MOANING" FROM FRONT DIFFERENTIAL WHILE IN 2-WHEEL DRIVE - VEHICLES BUILT THROUGH 4/15/1999 ^ AXLE - "MOANING" NOISE FROM FRONT DIFFERENTIAL WHILE IN 2-WHEEL DRIVE VEHICLES BUILT THROUGH 4/15/1999 FORD: 1997-1999 EXPEDITION, F-150, F-250 LD LINCOLN: 1998-1999 NAVIGATOR ISSUE Some 4X4 vehicles built with center disconnect front axles may exhibit a "moaning" noise from the front differential while operating in 4X2 mode. The noise goes away when operating in 4X4 mode. This may be caused by the front differential side gears. ACTION Replace the front differential side gears with revised gears and replace the front differential pinion gears with revised gears. Refer to the following text for details. For vehicles that exhibit a front differential moan in 4X2 mode that goes away in 4X4 mode, replace both front axle side gears and both front axle pinion gears. Replace any worn or damaged pinion thrust washers and side gear washers. Refer to Section 205-03 of the appropriate model/year Workshop Manual for removal and installation procedures. PART NUMBER PART NAME XL3Z-4236-M Side Gears (2 Per Box) XL3Z-4215-M Pinion Gears (2 Per Box) DOAZ-4230-B Pinion Thrust washer C90Z-4228-B Side Gear washer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991403A Replace Axle Side Gears 1.4 Hrs. And Pinion Gears DEALER CODING CONDITION BASIC PART NO. CODE 4235 42 OASIS CODES: 509000, 597997, 702100 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pinion Gear: > 99-14-3 > Jul > 99 > Front Differential - Moaning Noise In 2WD Mode Pinion Gear: All Technical Service Bulletins Front Differential - Moaning Noise In 2WD Mode Article No. 99-14-3 07/12/99 ^ NOISE - "MOANING" FROM FRONT DIFFERENTIAL WHILE IN 2-WHEEL DRIVE - VEHICLES BUILT THROUGH 4/15/1999 ^ AXLE - "MOANING" NOISE FROM FRONT DIFFERENTIAL WHILE IN 2-WHEEL DRIVE VEHICLES BUILT THROUGH 4/15/1999 FORD: 1997-1999 EXPEDITION, F-150, F-250 LD LINCOLN: 1998-1999 NAVIGATOR ISSUE Some 4X4 vehicles built with center disconnect front axles may exhibit a "moaning" noise from the front differential while operating in 4X2 mode. The noise goes away when operating in 4X4 mode. This may be caused by the front differential side gears. ACTION Replace the front differential side gears with revised gears and replace the front differential pinion gears with revised gears. Refer to the following text for details. For vehicles that exhibit a front differential moan in 4X2 mode that goes away in 4X4 mode, replace both front axle side gears and both front axle pinion gears. Replace any worn or damaged pinion thrust washers and side gear washers. Refer to Section 205-03 of the appropriate model/year Workshop Manual for removal and installation procedures. PART NUMBER PART NAME XL3Z-4236-M Side Gears (2 Per Box) XL3Z-4215-M Pinion Gears (2 Per Box) DOAZ-4230-B Pinion Thrust washer C90Z-4228-B Side Gear washer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991403A Replace Axle Side Gears 1.4 Hrs. And Pinion Gears DEALER CODING CONDITION BASIC PART NO. CODE 4235 42 OASIS CODES: 509000, 597997, 702100 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Technical Service Bulletins > Page 6658 Pinion Gear: Testing and Inspection Rear axle universal joint flange runout should be checked when all other checks have failed to show the cause of vibration. Another cause of excessive rear axle universal joint flange runout is improper installation of the rear axle drive pinion seal. Check to see if the spring on the seal lip has been dislodged before replacing the differential ring gear and pinion. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear Pinion Gear: Service and Repair 8.8 Inch Ring Gear Removal 1. Remove the axle shafts. 2. Mark the driveshaft flange and rear axle companion flange for correct alignment during installation. 3. Remove the four driveshaft bolts and disconnect the driveshaft. Wire the driveshaft aside. 4. Wipe the lubricant from the internal working parts and visually inspect the parts for wear or damage. 5. Rotate the differential case to see if there is any roughness which would indicate damaged bearings or gears. 6. Position Dial Indicator with Bracketry and inspect ring gear backface runout. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6661 NOTE: - Specification shown is the maximum ring gear runout allowable. - There is a space between the anti-lock speed sensor ring and the ring gear for measuring ring gear backface runout. 7. Mark one differential bearing cap and the differential case for correct alignment during installation. CAUTION: The bearing caps must not be interchanged or rotated. 8. Loosen the differential case. (1) Loosen the bolts. (2) Loosen the bearing caps. NOTE: The direction and location of the triangles on the bearing caps must remain consistent during installation. 9. Use the (A) pry bar and (B) wood block to loosen the (C) differential case from the (D) axle housing. CAUTION: Place a wood block between the pry bar and the axle housing to protect the machined surface from damage. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6662 10. Remove the differential case. (1) Remove the bolts. (2) Remove the bearing caps. (3) Remove the differential case. 11. Install a Nm (Inch lbs) torque wrench on the pinion nut and record the torque required to maintain rotation of the pinion through several revolutions. 12. Use (B) Companion Flange Holding Tool to hold the (A) rear axle companion flange while removing the (C) pinion nut. 13. Mark the (A) rear axle companion flange in relation to the (B) drive pinion stem to ensure proper alignment during installation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6663 14. Use 2-Jaw Puller to remove the rear axle companion flange. 15. Remove the drive pinion. 16. Use a press and Pinion Bearing Cone Remover to remove the differential pinion bearing. 17. Remove the pinion seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6664 18. Remove the oil slinger and the outer differential pinion bearing. 19. If the pinion bearing cups are damaged, use a suitable brass drift to remove the differential bearing cups. NOTE: - Tap alternately on opposite sides of the cups to prevent them from cocking in the bore. - Do not remove the pinion bearing cups from the axle housing unless the pinion bearing cups are damaged. 20. Remove the 10 ring gear bolts. 21. Remove the differential ring gear. (1) Insert the drift into the bolt hole. (2) Tapping from side to side, remove the differential ring gear. NOTE: Use a drift that will bottom out in the ring gear bolt holes to separate the differential ring gear from the differential case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6665 22. Remove the speed sensor ring. NOTE: The speed sensor ring cannot be reused once removed. 23. Install the differential case. (1) Position the differential case assembly, including shims, in the axle housing. (2) Install the differential bearing caps. (3) Install the bolts. 24. Position Dial Indicator with Bracketry. (1) Rotate the differential case to ensure the differential bearings are properly seated. (2) Position Dial Indicator with Bracketry. 25. Measure the differential case runout without the ring gear. (1) Rotate the differential case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6666 (2) Check and note the differential case runout. NOTE: - Specification shown is the maximum differential case runout allowable. - If runout is within specification, install a new ring gear and pinion. If runout exceeds specification, the ring gear is true and the concern is due to either a damaged differential case or differential bearings. Inspect the differential bearings. If the differential bearings are not damaged, replace both the differential case and the differential bearings. 26. Remove the differential case from the axle housing and remove the differential bearings using 2-Jaw Puller and Step Plate. 27. Use Differential Side Bearing Replacer to install the new differential bearings on the differential case. 28. Install the differential case. (1) Position the differential case assembly, including shims, in the axle housing. (2) Install the differential bearing caps. (3) Install the bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6667 29. Measure the differential case runout without the ring gear. - Check the case runout again with the new differential bearings. If the runout is now within 0.076 mm (0.003 in), use the new differential bearings for assembly. If the runout is still excessive, the differential case is damaged and should be replaced. NOTE: Specification shown is the maximum differential case runout allowable. 30. Remove the differential case from the axle housing. Installation 1. Press the new (A) anti-lock speed sensor ring and the (B) ring gear on the differential case. 2. Install the ring gear bolts. - Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to ring gear bolts. 3. If the pinion beating cups were removed, install the pinion bearing cups with Pinion Bearing Cup Replacer, ensuring the pinion bearing cups are fully seated. NOTE: Differential pinion bearings and cups must be replaced in sets. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6668 4. Select the proper pinion adjustment shim. See: Specifications/Mechanical Specifications CAUTION: When selecting the pinion adjustment shim the correct shim must be installed or damage may occur. 5. Use a press and Inner Pinion Bearing Cone Replacer to press the differential pinion bearing until it is firmly seated on the pinion and pinion adjustment shim. NOTE: The same pinion bearing used in this procedure must be used in the final axle assembly. 6. Place a new collapsible spacer on the pinion shaft. 7. Lubricate the lip of the pinion seal and the splines on the pinion shaft with Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 8. Install the pinion seal. (1) Install the outer differential pinion bearing. (2) Install the oil slinger in the axle housing. (3) Install the (A) pinion seal with (B) Pinion Seal Replacer. CAUTION: Installation without the proper tool may result in early seal failure. If the pinion seal becomes cocked during installation, remove it and install a new one. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6669 9. Position the pinion in the axle housing. 10. Align the (A) rear axle companion flange with the (B) drive pinion shaft. NOTE: Disregard the scribe marks if a new rear axle companion flange is being installed. 11. Use Companion Flange Replacer to install the rear axle companion flange. 12. Position the new pinion nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6670 13. Use (B) Companion Flange Holding Tool to hold the (A) rear axle companion flange while tightening the (C) pinion nut. - Tighten the pinion nut, rotating the pinion occasionally to make sure cone and roller bearings are seating properly. Take frequent cone and roller bearing torque preload readings until the original recorded preload readings are obtained by rotating the pinion with a Nm (inch.lbs) torque wrench. - If the original recorded preload is lower than specification (original bearings 0.8-1.5 Nm [8-14 inch.lbs], new bearings 1.8-3.3 Nm [16-29 inch.lbs]), tighten to specification. If the preload is higher than specification, tighten to original reading as recorded. 14. Remove the Companion Flange Holding Tool. 15. Set up differential case. CAUTION: When installing the differential case, the differential case adjustment must be performed or damage may occur. 16. Install differential case and shims into the axle housing. 17. Install the bearing caps and bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6671 18. Rotate the differential case to make sure it rotates freely. 19. Install the axle shafts. 20. Position the rear driveshaft and align the marks on the rear axle companion flange. 21. Install the four driveshaft bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6672 Pinion Gear: Service and Repair 9.75 Inch Ring Gear Removal 1. Remove the axle shafts. 2. Mark the driveshaft flange and rear axle companion flange for correct alignment during installation. 3. Remove the four driveshaft bolts and disconnect the driveshaft. Wire the driveshaft aside. 4. Rotate the differential case to see if there is any roughness which would indicate damaged bearings or gears. 5. Position Dial Indicator/Magnetic Base and measure the ring gear backface runout. NOTE: - There is a space between the anti-lock speed sensor ring and the ring gear for measuring ring gear backface runout. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6673 - Specification shown is the maximum ring gear backface runout allowable. 6. Mark one differential bearing cap in relation to the axle housing to ensure the differential bearing caps are installed in their original positions during installation. CAUTION: The differential bearing caps must not be interchanged or rotated. NOTE: The direction and location of the triangles on the bearing caps must remain in the same position for installation. 7. Loosen the differential bearing caps. (1) Loosen the differential bearing cap bolts. (2) Loosen the caps. 8. Use a pry bar and a wood block to loosen the differential case. CAUTION: Place a wood block between the pry bar and the axle housing to protect the machined surface from damage. 9. Remove the differential case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6674 (1) Remove the bolts. (2) Remove the differential bearing caps. (3) Remove the differential case. 10. Remove the ring gear bolts. 11. Use a drift that will bottom out in the ring gear bolt holes to separate the differential ring gear from the differential case. 12. Remove the speed sensor ring. NOTE: The speed sensor ring cannot be reused once removed. 13. Install a Nm (inch.lbs) torque wrench on the pinion nut and record the torque required to maintain rotation of the pinion through several revolutions. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6675 14. Use (B) Companion Flange Holding Tool to hold the (A) rear axle companion flange while removing the (C) pinion nut. 15. Remove Companion Flange Holding Tool. 16. Index the (A) rear axle companion flange to the (B) pinion stem to ensure proper alignment during installation. 17. Use 2-Jaw Puller to remove the rear axle companion flange. CAUTION: Before proceeding, place a drain pan under the axle housing. 18. Install Pinion Shaft Thread Protector and drive the pinion out of the rear of the axle housing with a soft-faced hammer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6676 19. Use a press and Pinion Bearing Cone Remover to remove the differential pinion bearing. 20. Remove the pinion seal. 21. Remove the oil slinger and the outer differential pinion bearing. 22. If the pinion bearing cups are damaged, use a suitable brass drift to remove the differential bearing cups. NOTE: - Do not remove the pinion bearing cups from the axle housing unless the pinion bearing cups are damaged. - Tap alternately on opposite sides of the cups to prevent them from cocking in the bore. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6677 23. Install the differential case without the ring gear. (1) Position the differential case, including the differential bearing shims. (2) Position the differential bearing caps (3) Install the bolts. 24. Position Dial Indicator/Magnetic Base. (1) Rotate the differential case to ensure the differential bearings are properly seated. (2) Position Dial Indicator/Magnetic Base. 25. Measure the differential case runout. (1) Rotate the differential case. (2) Measure and record the differential case runout. NOTE: - If runout is within specification, install a new ring gear and pinion. If runout exceeds specification, the ring gear is true and the concern is due to either a damaged differential case or differential bearings. Inspect the differential bearings. If the differential bearings are not damaged, replace both the differential case and the differential bearings. - Specification shown is the maximum differential case runout allowable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6678 26. Remove the Dial Indicator/Magnetic Base. 27. Remove the differential case from the axle housing. (1) Remove the bolts. (2) Remove the differential bearing caps. (3) Remove the differential case. 28. Use 2-Jaw Puller For Differential Case Bearings along with Step Plate to remove the differential case bearings. 29. Use Differential Bearing Cone Replacer to install the new differential case bearings. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6679 30. Install the differential case without the ring gear. (1) Position the differential case, including the differential bearing shims. (2) Position the differential bearing caps. (3) Install the differential bearings cap bolts. 31. Measure and record the differential case runout. (1) Rotate the differential case. (2) Measure and record the differential case runout. NOTE: If the runout is now within specification, use the new differential case bearings for assembly. If the runout is still excessive, the differential case is damaged and should be replaced. - Specification shown is the maximum differential case runout allowable. 32. Remove the differential case from the axle housing. (1) Remove the bolts. (2) Remove the differential bearing caps. (3) Remove the differential case. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6680 1. If the pinion bearing cups were removed, use Pinion Bearing Cup Replacer along with Driver Handle to install the outer differential pinion bearing cup and ensure cup is fully seated. NOTE: Differential pinion bearings and cups must be replaced in sets. 2. If the pinion bearing cups were removed, use Pinion Bearing Cup Replacer along with Driver Handle to install the inner differential pinion bearing cup and ensure cup is fully seated. 3. Select the proper pinion adjustment shim. See: Specifications/Mechanical Specifications CAUTION: When selecting the pinion adjustment shim, the correct shim must be installed or damage may occur. 4. Use a press and Inner Pinion Bearing Cone Replacer to press the differential pinion bearing until it is firmly seated on the pinion and pinion adjustment shim. 5. Place a new collapsible spacer on the pinion shaft. 6. Lubricate the lip of the pinion seal and the splines on the pinion shaft with Motorcraft Synthetic Rear Axle Lubricant F112-19580-B or equivalent meeting Ford Specification WSL-M2C192-A. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6681 7. Install the pinion seal. (1) Install the outer differential pinion bearing. (2) Install the oil slinger. (3) Install the (A) pinion seal using (B) Pinion Seal Replacer. CAUTION: Installation without the proper tool can result in early seal failure. If the seal becomes cocked during installation, remove it and install a new one. 8. Position the pinion in the axle housing. 9. Align the (A) rear axle companion flange with the (B) pinion shaft. NOTE: Disregard the scribe marks if a new rear axle companion flange is being installed. 10. Use Companion Flange Replacer to install the rear axle companion flange. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6682 11. Use Companion Flange Holding Tool to hold the rear axle companion flange while tightening the pinion nut and set pinion bearing preload. - Tighten the pinion nut rotating the pinion occasionally to ensure the differential pinion bearings are seating properly. Take frequent differential pinion bearing preload readings until the desired preload reading is obtained by rotating the pinion with a Nm (inch.lbs) torque wrench. - If the original recorded preload is lower than specification, tighten to specification. If the original recorded preload is higher than specification, tighten to original reading as recorded. CAUTION: Never back off the pinion nut to reduce preload. If reduced preload is required, install a new collapsible spacer and pinion nut. NOTE: Pinion bearing preload is set by tightening the pinion nut. 12. Remove Companion Flange Holding Tool. 13. Press the new (A) anti-lock speed sensor ring and the (B) ring gear onto the differential case. NOTE: Thread two bolts into the ring gear while pressing to align the bolt holes. 14. Install the remaining ring gear bolts. - Apply Stud and Bearing Mount EOAZ-19551BA or equivalent meeting Ford specification WSK-M2G349-A1 to the ring gear bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6683 15. Position the differential case in the axle housing. 16. Set ring gear backlash. CAUTION: Ring gear backlash setup must be performed or damage may occur. 17. Set differential bearing preload. 18. Position the rear driveshaft and align the marks on the rear axle companion flange. 19. Install the four driveshaft bolts. 20. Install the axle shafts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Tools and Equipment > 8.8 Inch Ring Gear Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Tools and Equipment > 8.8 Inch Ring Gear > Page 6686 Pinion Gear: Tools and Equipment 9.75 Inch Ring Gear Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear Ring Gear: Service and Repair 8.8 Inch Ring Gear Removal 1. Remove the axle shafts. 2. Mark the driveshaft flange and rear axle companion flange for correct alignment during installation. 3. Remove the four driveshaft bolts and disconnect the driveshaft. Wire the driveshaft aside. 4. Wipe the lubricant from the internal working parts and visually inspect the parts for wear or damage. 5. Rotate the differential case to see if there is any roughness which would indicate damaged bearings or gears. 6. Position Dial Indicator with Bracketry and inspect ring gear backface runout. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6691 NOTE: - Specification shown is the maximum ring gear runout allowable. - There is a space between the anti-lock speed sensor ring and the ring gear for measuring ring gear backface runout. 7. Mark one differential bearing cap and the differential case for correct alignment during installation. CAUTION: The bearing caps must not be interchanged or rotated. 8. Loosen the differential case. (1) Loosen the bolts. (2) Loosen the bearing caps. NOTE: The direction and location of the triangles on the bearing caps must remain consistent during installation. 9. Use the (A) pry bar and (B) wood block to loosen the (C) differential case from the (D) axle housing. CAUTION: Place a wood block between the pry bar and the axle housing to protect the machined surface from damage. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6692 10. Remove the differential case. (1) Remove the bolts. (2) Remove the bearing caps. (3) Remove the differential case. 11. Install a Nm (Inch lbs) torque wrench on the pinion nut and record the torque required to maintain rotation of the pinion through several revolutions. 12. Use (B) Companion Flange Holding Tool to hold the (A) rear axle companion flange while removing the (C) pinion nut. 13. Mark the (A) rear axle companion flange in relation to the (B) drive pinion stem to ensure proper alignment during installation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6693 14. Use 2-Jaw Puller to remove the rear axle companion flange. 15. Remove the drive pinion. 16. Use a press and Pinion Bearing Cone Remover to remove the differential pinion bearing. 17. Remove the pinion seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6694 18. Remove the oil slinger and the outer differential pinion bearing. 19. If the pinion bearing cups are damaged, use a suitable brass drift to remove the differential bearing cups. NOTE: - Tap alternately on opposite sides of the cups to prevent them from cocking in the bore. - Do not remove the pinion bearing cups from the axle housing unless the pinion bearing cups are damaged. 20. Remove the 10 ring gear bolts. 21. Remove the differential ring gear. (1) Insert the drift into the bolt hole. (2) Tapping from side to side, remove the differential ring gear. NOTE: Use a drift that will bottom out in the ring gear bolt holes to separate the differential ring gear from the differential case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6695 22. Remove the speed sensor ring. NOTE: The speed sensor ring cannot be reused once removed. 23. Install the differential case. (1) Position the differential case assembly, including shims, in the axle housing. (2) Install the differential bearing caps. (3) Install the bolts. 24. Position Dial Indicator with Bracketry. (1) Rotate the differential case to ensure the differential bearings are properly seated. (2) Position Dial Indicator with Bracketry. 25. Measure the differential case runout without the ring gear. (1) Rotate the differential case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6696 (2) Check and note the differential case runout. NOTE: - Specification shown is the maximum differential case runout allowable. - If runout is within specification, install a new ring gear and pinion. If runout exceeds specification, the ring gear is true and the concern is due to either a damaged differential case or differential bearings. Inspect the differential bearings. If the differential bearings are not damaged, replace both the differential case and the differential bearings. 26. Remove the differential case from the axle housing and remove the differential bearings using 2-Jaw Puller and Step Plate. 27. Use Differential Side Bearing Replacer to install the new differential bearings on the differential case. 28. Install the differential case. (1) Position the differential case assembly, including shims, in the axle housing. (2) Install the differential bearing caps. (3) Install the bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6697 29. Measure the differential case runout without the ring gear. - Check the case runout again with the new differential bearings. If the runout is now within 0.076 mm (0.003 in), use the new differential bearings for assembly. If the runout is still excessive, the differential case is damaged and should be replaced. NOTE: Specification shown is the maximum differential case runout allowable. 30. Remove the differential case from the axle housing. Installation 1. Press the new (A) anti-lock speed sensor ring and the (B) ring gear on the differential case. 2. Install the ring gear bolts. - Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to ring gear bolts. 3. If the pinion beating cups were removed, install the pinion bearing cups with Pinion Bearing Cup Replacer, ensuring the pinion bearing cups are fully seated. NOTE: Differential pinion bearings and cups must be replaced in sets. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6698 4. Select the proper pinion adjustment shim. See: Specifications/Mechanical Specifications CAUTION: When selecting the pinion adjustment shim the correct shim must be installed or damage may occur. 5. Use a press and Inner Pinion Bearing Cone Replacer to press the differential pinion bearing until it is firmly seated on the pinion and pinion adjustment shim. NOTE: The same pinion bearing used in this procedure must be used in the final axle assembly. 6. Place a new collapsible spacer on the pinion shaft. 7. Lubricate the lip of the pinion seal and the splines on the pinion shaft with Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 8. Install the pinion seal. (1) Install the outer differential pinion bearing. (2) Install the oil slinger in the axle housing. (3) Install the (A) pinion seal with (B) Pinion Seal Replacer. CAUTION: Installation without the proper tool may result in early seal failure. If the pinion seal becomes cocked during installation, remove it and install a new one. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6699 9. Position the pinion in the axle housing. 10. Align the (A) rear axle companion flange with the (B) drive pinion shaft. NOTE: Disregard the scribe marks if a new rear axle companion flange is being installed. 11. Use Companion Flange Replacer to install the rear axle companion flange. 12. Position the new pinion nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6700 13. Use (B) Companion Flange Holding Tool to hold the (A) rear axle companion flange while tightening the (C) pinion nut. - Tighten the pinion nut, rotating the pinion occasionally to make sure cone and roller bearings are seating properly. Take frequent cone and roller bearing torque preload readings until the original recorded preload readings are obtained by rotating the pinion with a Nm (inch.lbs) torque wrench. - If the original recorded preload is lower than specification (original bearings 0.8-1.5 Nm [8-14 inch.lbs], new bearings 1.8-3.3 Nm [16-29 inch.lbs]), tighten to specification. If the preload is higher than specification, tighten to original reading as recorded. 14. Remove the Companion Flange Holding Tool. 15. Set up differential case. CAUTION: When installing the differential case, the differential case adjustment must be performed or damage may occur. 16. Install differential case and shims into the axle housing. 17. Install the bearing caps and bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6701 18. Rotate the differential case to make sure it rotates freely. 19. Install the axle shafts. 20. Position the rear driveshaft and align the marks on the rear axle companion flange. 21. Install the four driveshaft bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6702 Ring Gear: Service and Repair 9.75 Inch Ring Gear Removal 1. Remove the axle shafts. 2. Mark the driveshaft flange and rear axle companion flange for correct alignment during installation. 3. Remove the four driveshaft bolts and disconnect the driveshaft. Wire the driveshaft aside. 4. Rotate the differential case to see if there is any roughness which would indicate damaged bearings or gears. 5. Position Dial Indicator/Magnetic Base and measure the ring gear backface runout. NOTE: - There is a space between the anti-lock speed sensor ring and the ring gear for measuring ring gear backface runout. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6703 - Specification shown is the maximum ring gear backface runout allowable. 6. Mark one differential bearing cap in relation to the axle housing to ensure the differential bearing caps are installed in their original positions during installation. CAUTION: The differential bearing caps must not be interchanged or rotated. NOTE: The direction and location of the triangles on the bearing caps must remain in the same position for installation. 7. Loosen the differential bearing caps. (1) Loosen the differential bearing cap bolts. (2) Loosen the caps. 8. Use a pry bar and a wood block to loosen the differential case. CAUTION: Place a wood block between the pry bar and the axle housing to protect the machined surface from damage. 9. Remove the differential case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6704 (1) Remove the bolts. (2) Remove the differential bearing caps. (3) Remove the differential case. 10. Remove the ring gear bolts. 11. Use a drift that will bottom out in the ring gear bolt holes to separate the differential ring gear from the differential case. 12. Remove the speed sensor ring. NOTE: The speed sensor ring cannot be reused once removed. 13. Install a Nm (inch.lbs) torque wrench on the pinion nut and record the torque required to maintain rotation of the pinion through several revolutions. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6705 14. Use (B) Companion Flange Holding Tool to hold the (A) rear axle companion flange while removing the (C) pinion nut. 15. Remove Companion Flange Holding Tool. 16. Index the (A) rear axle companion flange to the (B) pinion stem to ensure proper alignment during installation. 17. Use 2-Jaw Puller to remove the rear axle companion flange. CAUTION: Before proceeding, place a drain pan under the axle housing. 18. Install Pinion Shaft Thread Protector and drive the pinion out of the rear of the axle housing with a soft-faced hammer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6706 19. Use a press and Pinion Bearing Cone Remover to remove the differential pinion bearing. 20. Remove the pinion seal. 21. Remove the oil slinger and the outer differential pinion bearing. 22. If the pinion bearing cups are damaged, use a suitable brass drift to remove the differential bearing cups. NOTE: - Do not remove the pinion bearing cups from the axle housing unless the pinion bearing cups are damaged. - Tap alternately on opposite sides of the cups to prevent them from cocking in the bore. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6707 23. Install the differential case without the ring gear. (1) Position the differential case, including the differential bearing shims. (2) Position the differential bearing caps (3) Install the bolts. 24. Position Dial Indicator/Magnetic Base. (1) Rotate the differential case to ensure the differential bearings are properly seated. (2) Position Dial Indicator/Magnetic Base. 25. Measure the differential case runout. (1) Rotate the differential case. (2) Measure and record the differential case runout. NOTE: - If runout is within specification, install a new ring gear and pinion. If runout exceeds specification, the ring gear is true and the concern is due to either a damaged differential case or differential bearings. Inspect the differential bearings. If the differential bearings are not damaged, replace both the differential case and the differential bearings. - Specification shown is the maximum differential case runout allowable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6708 26. Remove the Dial Indicator/Magnetic Base. 27. Remove the differential case from the axle housing. (1) Remove the bolts. (2) Remove the differential bearing caps. (3) Remove the differential case. 28. Use 2-Jaw Puller For Differential Case Bearings along with Step Plate to remove the differential case bearings. 29. Use Differential Bearing Cone Replacer to install the new differential case bearings. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6709 30. Install the differential case without the ring gear. (1) Position the differential case, including the differential bearing shims. (2) Position the differential bearing caps. (3) Install the differential bearings cap bolts. 31. Measure and record the differential case runout. (1) Rotate the differential case. (2) Measure and record the differential case runout. NOTE: If the runout is now within specification, use the new differential case bearings for assembly. If the runout is still excessive, the differential case is damaged and should be replaced. - Specification shown is the maximum differential case runout allowable. 32. Remove the differential case from the axle housing. (1) Remove the bolts. (2) Remove the differential bearing caps. (3) Remove the differential case. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6710 1. If the pinion bearing cups were removed, use Pinion Bearing Cup Replacer along with Driver Handle to install the outer differential pinion bearing cup and ensure cup is fully seated. NOTE: Differential pinion bearings and cups must be replaced in sets. 2. If the pinion bearing cups were removed, use Pinion Bearing Cup Replacer along with Driver Handle to install the inner differential pinion bearing cup and ensure cup is fully seated. 3. Select the proper pinion adjustment shim. See: Specifications/Mechanical Specifications CAUTION: When selecting the pinion adjustment shim, the correct shim must be installed or damage may occur. 4. Use a press and Inner Pinion Bearing Cone Replacer to press the differential pinion bearing until it is firmly seated on the pinion and pinion adjustment shim. 5. Place a new collapsible spacer on the pinion shaft. 6. Lubricate the lip of the pinion seal and the splines on the pinion shaft with Motorcraft Synthetic Rear Axle Lubricant F112-19580-B or equivalent meeting Ford Specification WSL-M2C192-A. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6711 7. Install the pinion seal. (1) Install the outer differential pinion bearing. (2) Install the oil slinger. (3) Install the (A) pinion seal using (B) Pinion Seal Replacer. CAUTION: Installation without the proper tool can result in early seal failure. If the seal becomes cocked during installation, remove it and install a new one. 8. Position the pinion in the axle housing. 9. Align the (A) rear axle companion flange with the (B) pinion shaft. NOTE: Disregard the scribe marks if a new rear axle companion flange is being installed. 10. Use Companion Flange Replacer to install the rear axle companion flange. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6712 11. Use Companion Flange Holding Tool to hold the rear axle companion flange while tightening the pinion nut and set pinion bearing preload. - Tighten the pinion nut rotating the pinion occasionally to ensure the differential pinion bearings are seating properly. Take frequent differential pinion bearing preload readings until the desired preload reading is obtained by rotating the pinion with a Nm (inch.lbs) torque wrench. - If the original recorded preload is lower than specification, tighten to specification. If the original recorded preload is higher than specification, tighten to original reading as recorded. CAUTION: Never back off the pinion nut to reduce preload. If reduced preload is required, install a new collapsible spacer and pinion nut. NOTE: Pinion bearing preload is set by tightening the pinion nut. 12. Remove Companion Flange Holding Tool. 13. Press the new (A) anti-lock speed sensor ring and the (B) ring gear onto the differential case. NOTE: Thread two bolts into the ring gear while pressing to align the bolt holes. 14. Install the remaining ring gear bolts. - Apply Stud and Bearing Mount EOAZ-19551BA or equivalent meeting Ford specification WSK-M2G349-A1 to the ring gear bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6713 15. Position the differential case in the axle housing. 16. Set ring gear backlash. CAUTION: Ring gear backlash setup must be performed or damage may occur. 17. Set differential bearing preload. 18. Position the rear driveshaft and align the marks on the rear axle companion flange. 19. Install the four driveshaft bolts. 20. Install the axle shafts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Tools and Equipment > 8.8 Inch Ring Gear Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Tools and Equipment > 8.8 Inch Ring Gear > Page 6716 Ring Gear: Tools and Equipment 9.75 Inch Ring Gear Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Inspection Seals and Gaskets: Service and Repair Inspection Leaks at the axle drive pinion seal originate for the following reasons: - Seal was not properly installed. - Poor quality seal journal surface. Any damage to the seal bore (dings, dents, gouges, or other imperfections) will distort the seal casing and allow leakage past the outer edge of the axle drive pinion seal. The axle drive pinion seal can be torn, cut, or gouged if it is not assembled carefully. The spring that holds the axle drive pinion seal against the axle universal joint flange may be knocked out and allow leakage past the lip. The rubber lips can occasionally become hard (like plastic) with cracks at the oil lip contact point. The contact point on the axle universal joint flange may become black, indicating excessive heat. Marks, nicks, gouges, or rough surface texture on the seal journal of the axle universal joint flange will also cause leaks. Axle drive pinion seal wear 1.27 mm (0.050 inch) or greater is considered excessive. The axle universal joint flange should be replaced if any of these conditions exist. Metal chips or sand trapped at the sealing lip may also cause oil leaks. This can cause a wear groove on the axle universal joint flange and heavy pinion seal wear. When a seal leak occurs, replace the seal and check the vent and the vent hose to make sure they are clean and free of debris. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Inspection > Page 6721 Seals and Gaskets: Service and Repair Ford REMOVAL 1. Remove the front axle universal joint flange. 2. Remove the pinion seal. CAUTION: Do not damage the front axle housing. INSTALLATION 1. Clean the pinion seal bore and use (B) Pinion Seal Replacer to install the (A) pinion seal. 2. Install front axle universal joint flange. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Inspection > Page 6722 Seals and Gaskets: Service and Repair Rear REMOVAL 1. Remove the rear axle companion flange. 2. Pry up on the metal flange of the pinion seal and remove the pinion seal. INSTALLATION 1. Lubricate the new pinion seal. - Use Premium Long-Life Grease XG-1-C or XG-1-K or equivalent meeting Ford specification ESA-M1C75-B. 2. Use (A) Pinion Seal Replacer to install the (B) pinion seal. CAUTION: If the pinion seal becomes misaligned during installation, remove the seal and replace. 3. Install the rear axle companion flange. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Page 6723 Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair Axle Bearing: Service and Repair REMOVAL 1. Remove the axle shaft. 2. Use Impact Slide Hammer along with Axle Wheel Bearing Puller to remove the rear axle bearing and axle shaft oil seal. NOTE: If the axle shaft oil seal is leaking, the axle housing vent may be plugged. INSTALLATION 1. Lubricate the new rear axle bearing. - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 2. Use Axle Wheel Bearing Replacer along with Driver Handle to install the rear axle bearing. 3. Lubricate the lip of the new axle shaft oil seal. - Use Premium Long-Life Grease XG-1-C or XG-1-K or equivalent meeting Ford specification ESA-M1C75-B. 4. Use Hub Seal Replacer along with Driver Handle to install the axle shaft oil seal. 5. Install the axle shafts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Page 6728 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Pivot Bushing > Component Information > Service and Repair Axle Pivot Bushing: Service and Repair REMOVAL 1. Remove the front drive axle assembly. 2. Position the tube bushing removal tools. (1) Position the Bushing Remover/Replacer Cup. (2) Position the Drawbolt. (3) Thread the Bushing Remover Adapter on Drawbolt. 3. Tighten the Drawbolt to remove the tube bushing. INSTALLATION 1. Position the tube bushing and the tube bushing installation tools. (1) Position the tube bushing. (2) Position the Gauge Ring. (3) Position the Bushing Replacer Collet. (4) Position the Bushing Remover/Replacer Cup. (5) Position the Drawbolt. (6) Thread the Bushing Replacer Adapter on the Drawbolt. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Pivot Bushing > Component Information > Service and Repair > Page 6732 2. Tighten the Drawbolt until the Bushing Replacer Collet contacts the axle tube. - Remove the tools 3.Install the front drive axle assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Pivot Bushing > Component Information > Service and Repair > Page 6733 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Mechanical Specifications Axle Shaft: Mechanical Specifications OPERATIONAL SPECIFICATIONS Halfshaft Assembled Length ........................................................................................................................................................ 417.25 mm (16.43 inch) TORQUE SPECIFICATIONS Front Drive Halfshaft Bolts ........................................................................................................................................................ 68-92 Nm (50-67 ft. lbs.) Hub Nut ....................................................................................................... ....................................................................... 255-345 Nm (188-254 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Mechanical Specifications > Page 6739 Axle Shaft: Capacity Specifications Outboard .............................................................................................................................................. ....................................... 165 grams (5.82 ounces) Inboard ............................................................... ......................................................................................................................... 235 grams (8.29 ounces) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 6740 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 6741 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 6742 Axle Shaft: Description and Operation The front wheel driveshaft and joints transmit equal engine torque from the axle to both front wheels. The front wheel driveshaft and joints use a constant velocity (CV) joint, at both the inboard and outboard ends, for smooth operation. The CV joints rotate at approximately one-third the speed of a driveshaft and do not normally contribute to any rotational vibration that may occur. The only replaceable components of the front wheel driveshaft and joint are: - Front wheel driveshaft joint boots (inboard and outboard). Replacement kit includes front wheel driveshaft joint boots and clamps, snap rings, retainer ring and grease. - Inboard CV joint (plunge type). - Side shaft. Replacement includes the outboard front wheel halfshaft joint (fixed type), outboard boot and clamps, front wheel excluder seal (assembled on the interconnecting shaft). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 6743 Axle Shaft: Testing and Inspection 1. Inspect the front wheel halfshaft joint boots for evidence of cracks, tears, or splits. NOTE: - Constant velocity (CV) front wheel halfshaft joints should not be replaced unless disassembly and inspection reveals unusual wear. - While inspecting the front wheel halfshaft joint boots, watch for indentations ("dimples") in the boot convolutions. Indentation must be removed. 2. Inspect the underbody for any indication of grease splatter near the front wheel halfshaft joint boots, outboard and inboard locations. This is an indication of front wheel halfshaft joint boot and/or front wheel halfshaft joint boot clamp damage. 3. Inspect for inboard front wheel halfshaft joint stub shaft pilot bearing housing seal leakage at the inboard front wheel halfshaft joint. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type Axle Shaft: Service and Repair Axle Shaft Assembly, Constant Velocity Type Removal and Installation REMOVAL 1. Loosen the lug nuts. (1) Remove the center cap. (2) With the weight of the vehicle on the wheels, loosen the lug nuts. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and the wheel bearings. 2. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 3. Remove the wheel and tire assembly. (1) Remove the lug nuts. (2) Remove the wheel and tire assembly. 4. Remove the hub nut. (1) Remove the cotter pin. (2) Remove the retainer. (3) Remove the hub nut. 5. Position the front disc brake caliper aside. (1) Remove the two caliper bolts. (2) Lift the front disc brake caliper off the front disc brake caliper anchor plate and position aside. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6746 6. Remove the upper ball joint castellated nut. (1) Remove the cotter pin. (2) Remove the castellated nut. 7. Use Pitman Arm Puller to separate the front wheel knuckle from the front suspension upper arm. 8. Remove the six front wheel driveshaft and joint bolts. 9. Separate the front wheel driveshaft and joint from the hub and remove the front wheel driveshaft and joint from the vehicle. CAUTION: Use caution to avoid damaging the hub seal when removing the front drive halfshaft. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6747 INSTALLATION 1. Install the six halfshaft bolts. 2. Install the caliper. 3. Install the front axle hub. (1) Install the front axle hub nut. (2) Install the retainer. (3) Install the cotter pin. 4. Install the front suspension arm upper ball joint castellated nut. (1) Position the front wheel knuckle. (2) Install the upper ball joint castellated nut. Install a new cotter pin. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6748 5. Install the tire and wheel assembly. (1) Position the tire and wheel assembly. (2) Install the lug nuts and lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. (3) Tighten in sequence the lug nuts. (4) Install the wheel cover. Disassembly 1. Remove the halfshaft and joint. 2. Slide the two inboard clamp protectors off the boot clamps. 3. Remove the two inboard boot clamps. CAUTION: Be careful not to damage the front wheel driveshaft joint boot. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6749 4. Slide the inboard front wheel driveshaft joint boot off the inboard CV joint housing. 5. Remove the retaining ring. 6. Remove the inboard CV joint housing. 7. Mark the inner race and the ball cage for assembly. 8. Remove the six balls. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6750 9. Remove the snap ring. 10. Remove the (A) inner race and (B) ball cage. 11. Remove the (A) inboard front wheel driveshaft joint boot and the (B) clamp protector. 12. Remove the two outboard boot clamps. (1) Remove the outboard clamp protectors. (2) Grip the boot clamps and peel the clamps away from the boot. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6751 13. Remove the outboard front wheel driveshaft joint boot. 14. Inspect for contaminated grease. 15. If grease is contaminated, clean and inspect the joint for wear. Replace the outboard CV joint and interconnecting shaft assembly if worn or damaged. Assembly 1. Pack the outboard CV joint with grease. (1) Use High Temp Constant Velocity Joint Grease E43Z-19590-A or equivalent meeting Ford specification ESP-MlC207-A provided in the boot kit. (2) Spread any remaining grease from service kit evenly inside the outboard boot. 2. Position the outboard front wheel driveshaft joint boot and outboard boot clamps. (1) Clean the front wheel driveshaft joint boot mounting surface. (2) Position the outboard front wheel driveshaft joint boot in the outboard CV joint grooves and position boot clamps. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6752 3. Use CV Boot Clamp Installer to install the boot clamps. NOTE: Tighten the through-bolt until installer is in the closed position. 4. Install the two outboard clamp protectors. 5. Position the (A) inboard clamp protector and the (B) boot clamp on the front wheel driveshaft and joint. 6. Position the inboard front wheel driveshaft joint boot. 7. Position the ball cage on the front wheel driveshaft and joint with the tapered end toward the front wheel driveshaft joint boot. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6753 8. Position the inner race on the front wheel driveshaft and joint with the counterbored end towards the front wheel driveshaft joint boot. NOTE: Line up the marks made during disassembly. 9. Install the snap ring. 10. Lubricate and position the six balls. - Use High Temp Constant Velocity Joint Grease E43Z-19590-A provided in the boot kit meeting Ford specification ESP-M1C207-A. 11. Position the clamp protector and the inboard boot clamp on the inboard CV joint housing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6754 12. Fill the inboard CV joint housing with 235 grams of grease. Use High Temp Constant Velocity Joint Grease E43Z-19590-A provided in the boot kit meeting Ford specification ESP-MlC207-A. 13. Position the (B) inboard CV joint housing and install the (A) retaining ring. 14. Remove any excess grease from the mating surface and position the inboard front wheel driveshaft joint boot. 15. Adjust the CV joint to boot spacing to specification. 16. Insert a dulled screwdriver blade to relieve built up air pressure in the front wheel driveshaft joint boot. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6755 NOTE: The air should be released only after adjusting the CV joint to boot spacing. 17. Use CV Boot Clamp Installer to install the two inboard boot clamps. 18. Position the clamp protectors over the inboard boot clamps. 19. Install the halfshaft and joint. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6756 Axle Shaft: Service and Repair Axle Shaft, Conventional Fixed/Floating 8.8 Inch Axle REMOVAL 1. Loosen the lug nuts. (1) Remove the center cap. (2) With the weight of the vehicle on the wheels, loosen the lug nuts. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and the wheel bearings. 2. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 3. Remove the wheel and tire assembly. (1) Remove the lug nuts. (2) Remove the wheel and tire assembly. 4. Remove the axle housing cover. (1) Loosen the axle housing cover bolts and drain the axle. (2) Remove the bolts. (3) Remove the axle housing cover. 5. Remove the rear disc brake rotors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6757 6. Remove the differential pinion shaft. (1) Remove the lock bolt. (2) Remove the differential pinion shaft. CAUTION: Once the differential pinion shaft has been removed, turning the differential case or an axle shaft will cause the differential pinion gears to fall out of the assembly. This could result in chipped or damaged components. 7. Remove the U-washers. (1) Push the axle shafts inboard. (2) Remove the U-washers. CAUTION: Do not damage the rubber O-rings in the axle shaft grooves. 8. Reinstall the differential pinion shaft. (1) Install the shaft. (2) Install the lock bolt finger tight. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6758 9. Remove the two axle shafts. CAUTION: Do not damage the axle shaft oil seal. INSTALLATION 1. Lubricate the lip of the axle shaft oil seal. - Use Premium Long-Life Grease XG-1-C or XG-1-K or equivalent meeting Ford specification ESA-M1C75-B. 2. Remove the differential pinion shaft. (1) Remove the lock bolt. (2) Remove the differential pinion shaft. CAUTION: Once the differential pinion shaft has been removed, turning the differential case or an axle shaft will cause the differential pinion gears to fall out of the assembly. This could result in chipped or damaged components. 3. Install the two axle shafts. CAUTION: Do not damage the axle shaft oil seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6759 4. Install the U-washers. (1) Position the two U-washers on the button end of the axle shaft. (2) Pull the axle shafts outward. CAUTION: Do not damage the rubber O-rings in the axle shaft grooves. 5. Install the differential pinion shaft. (1) Align the hole in the differential pinion shaft with the case lock bolt hole. (2) Install the lock bolt. 6. Install the rear disc brake rotors. 7. Install the rear axle housing cover and fill the differential carrier with the correct amount of specified lubricant. 8. Clean the wheel hub and mounting surfaces. WARNING: ALWAYS REMOVE ANY CORROSION, DIRT OR FOREIGN MATERIAL THAT MAY BE PRESENT ON THE MOUNTING SURFACES OF THE WHEEL OR THE SURFACE OF THE WHEEL HUB, BRAKE DRUM, OR BRAKE ROTOR THAT CONTACTS THE WHEEL. INSTALLING WHEELS WITHOUT PROPER METAL-TO-METAL CONTACT AT THE WHEEL MOUNTING SURFACES CAN CAUSE THE LUG NUT TO LOOSEN AND THE WHEEL TO COME OFF WHILE THE VEHICLE IS IN MOTION, CAUSING LOSS OF CONTROL. 9. Install the tire and wheel assembly. (1) Position the tire and wheel assembly. (2) Install the lug nuts and lower the vehicle. (3) Tighten the lug nuts. (4) Install the center cap. NOTE: If equipped with air suspension, reactivate the system by turning the air suspension switch on. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6760 9.75 Inch Axle REMOVAL 1. Loosen the lug nuts. (1) Remove the center cap. (2) With the weight of the vehicle on the wheels, loosen the lug nuts. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and the wheel bearings. 2. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 3. Remove the wheel and tire assembly. (1) Remove the lug nuts. (2) Remove the wheel and tire assembly. 4. Remove the axle housing cover. (1) Remove the axle housing cover bolts and drain the axle. (2) Remove the axle housing cover. 5. Remove the rear disc brake rotors. 6. Remove the differential pinion shaft. (1) Remove the lock bolt. (2) Remove the differential pinion shaft. CAUTION: Once the differential pinion shaft has been removed, turning the differential case or an axle shaft will cause the differential pinion gears to fall out of the assembly. This could result in chipped or damaged components. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6761 7. Remove the U-washers. (1) Push the axle shafts inboard. (2) Remove the U-washers. CAUTION: Do not damage the rubber O-rings in the axle shaft grooves. 8. Reinstall the differential pinion shaft. (1) Install the shaft. (2) Install the lock bolt finger tight. 9. Remove the two axle shafts. CAUTION: Do not damage the axle shaft oil seal. INSTALLATION 1. Lubricate the lip of the axle shaft oil seal. - Use Premium Long-Life Grease XG-1-C or XG-1-K or equivalent meeting Ford specification ESA-M1C75-B. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6762 2. Remove the differential pinion shaft. (1) Remove the lock bolt. (2) Remove the differential pinion shaft. CAUTION: Once the differential pinion shaft has been removed, turning the differential case or an axle shaft will cause the differential pinion gears to fall out of the assembly. This could result in chipped or damaged components. 3. Install the two axle shafts. CAUTION: Do not damage the axle shaft oil seal. 4. Install the U-washers. (1) Position the two U-washers on the button end of the axle shaft. (2) Pull the axle shahs outward. CAUTION: Do not damage the rubber O-rings in the axle shaft grooves. 5. Install the differential pinion shaft. (1) Align the hole in the differential pinion shaft with the case lock bolt hole. (2) Install the lock bolt. 6. Install the rear disc brake rotors. 7. Install the rear axle housing cover and fill the differential carrier with the correct amount of specified lubricant. 8. Clean the wheel hub and mounting surfaces. WARNING: ALWAYS REMOVE ANY CORROSION, DIRT OR FOREIGN MATERIAL THAT MAY BE PRESENT ON THE MOUNTING SURFACES OF THE WHEEL OR THE SURFACE OF THE WHEEL HUB, BRAKE DRUM, OR BRAKE ROTOR THAT CONTACTS THE WHEEL. INSTALLING WHEELS WITHOUT PROPER METAL-TO-METAL CONTACT AT THE WHEEL MOUNTING SURFACES CAN CAUSE THE LUG NUT TO LOOSEN AND THE WHEEL TO COME OFF WHILE THE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6763 VEHICLE IS IN MOTION, CAUSING LOSS OF CONTROL. 9. Install the tire and wheel assembly. (1) Position the tire and wheel assembly. (2) Install the lug nuts and lower the vehicle. (3) Tighten the lug nuts. (4) Install the center cap. NOTE: If equipped with air suspension, reactivate the system by turning the air suspension switch on. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6768 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6769 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6770 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6771 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6772 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6773 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6774 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6775 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6776 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6777 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6778 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6779 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6780 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6781 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6782 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6783 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6784 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6785 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6786 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6787 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6788 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6789 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6790 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6791 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6792 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6793 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6794 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6795 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6796 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6797 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6798 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6799 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6800 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6801 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6802 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6803 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6804 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6805 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6806 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6807 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6808 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6809 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6810 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6811 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6812 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6813 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6814 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6815 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6816 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6817 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6818 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6819 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6820 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6821 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6822 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6823 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6824 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6825 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6826 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6827 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6828 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6829 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6830 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6831 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6832 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6833 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6834 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6835 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6836 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6837 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6838 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6839 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6840 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6841 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6842 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6843 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6844 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6845 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6846 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6847 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6848 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6849 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6850 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6851 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6852 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6853 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6854 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6855 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6856 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6857 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6858 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6859 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6860 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6861 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6862 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Page 6863 Wheel Bearing: Specifications ^ Lubricate the new rear axle bearing. Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. ^ Lubricate the lip of the new axle shaft oil seal. Use Premium Long-Life Grease XG-1-C or XG-1-K or equivalent meeting Ford specification ESA-M1C75-B. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications TORQUE SPECIFICATIONS Front Axle Hub Nut ........................................................................................................................................................... 255-345 Nm (188-254 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Companion Flange > Component Information > Service and Repair > Front Companion Flange: Service and Repair Front REMOVAL WARNING: TO ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. CAUTION: This operation disturbs the differential pinion bearing preload. This preload must be carefully reset when assembling. 1. Raise and support the vehicle. 2. Index mark the front driveshaft to the front axle universal joint flange. 3. Disconnect the front driveshaft. (1) Remove the four bolts. (2) Carefully disconnect the front driveshaft. CAUTION: Do not allow the driveshaft to hang unsupported. 4. Use an inch lbs torque wrench to measure the torque required to maintain rotation of the pinion and record the measurement for reference during installation. 5. Mark the front axle universal joint flange and index it to the pinion stem. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Companion Flange > Component Information > Service and Repair > Front > Page 6873 6. Loosen the pinion nut. (1) Position Companion Flange Holding Tool and install two companion flange holding tool bolts. (2) Loosen the pinion nut. 7. Remove the front axle universal joint flange. (1) With (A) pinion nut still engaged by a few threads, install (B) 2-Jaw Puller. (2) Remove the front axle universal joint flange. CAUTION: Before proceeding, place a drain pan under the front axle housing. 8. Inspect the front axle universal joint flange for burrs and replace as necessary. Make sure that surfaces of the front axle universal joint flange have not been damaged during removal. The end of the front axle universal joint flange that contacts the bearing cone, the nut counterbore and the seal surface must be smooth and free of nicks. 9. Check the splines on the pinion stem to be sure they are free of burrs. If burrs are evident, remove them with a fine crocus cloth. Working in a rotating motion, wipe the pinion clean. INSTALLATION 1. Lubricate the flange yoke seal splines and seal. - Use Motorcraft SAE 75W90 4x4 Axle Lubricant XY-75W90-QL or equivalent meeting Ford specification WSP-M2C201-A. 2. Align index marks and position the front axle universal joint flange onto pinion shaft. CAUTION: The universal joint flange must never be hammered on or installed with power tools. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Companion Flange > Component Information > Service and Repair > Front > Page 6874 3. Using Companion Flange Replacer, install the front axle universal joint flange. NOTE: Rotate the pinion occasionally to ensure proper differential pinion bearing seating. 4. Install the pinion nut. (1) Position Companion Flange Holding Tool and install two companion flange holding tool bolts. (2) Tighten the pinion nut. NOTE: If the original recorded preload is less than specification, tighten to specification. If the preload is higher than the specification, tighten to original reading as recorded. Never back off the pinion nut to reduce preload. If reduced preload is required, a new differential drive pinion collapsible spacer and pinion nut must be installed. Take frequent differential pinion bearing torque preload readings until the original recorded or specified preload reading is obtained. 5. Align index marks then attach the front driveshaft. 6. Inspect and fill the differential fluid. - Use Motorcraft SAE 75W90 4x4 Axle Lubricant XY-75W90-QL or equivalent meeting Ford specification WSP-M2C201-A. 7. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Companion Flange > Component Information > Service and Repair > Front > Page 6875 Companion Flange: Service and Repair Rear Axle REMOVAL NOTE: The rear wheels and brake rotors must be removed to prevent brake drag during drive pinion bearing preload adjustment. 1. Remove the rear brake rotors. 2. Mark the driveshaft flange and rear axle companion flange for correct alignment during installation. 3. Remove the four driveshaft bolts and disconnect the driveshaft. Wire the driveshaft aside. 4. Install a torque wrench on the pinion nut and record the torque required to maintain rotation of the pinion through several revolutions. 5. Use (B) Companion Flange Holding Tool to hold the (A) rear axle companion flange while removing the (C) pinion nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Companion Flange > Component Information > Service and Repair > Front > Page 6876 6. Mark the (A) driveshaft rear axle companion flange in relation to the (B) drive pinion stem to insure proper alignment during installation. 7. Use Differential Side Bearing Puller to remove the rear axle companion flange. INSTALLATION 1. Lubricate the rear axle companion flange splines. - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 2. Align the (A) rear axle companion flange with the (B) drive pinion shaft. NOTE: Disregard the scribe marks if a new rear axle companion flange is being installed. 3. Use Companion Flange Replacer to install the rear axle companion flange. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Companion Flange > Component Information > Service and Repair > Front > Page 6877 4. Position the new pinion nut. 5. Use (B) Companion Flange Holding Tool to hold the (A) rear axle companion flange while tightening the (C) pinion nut. - Tighten the pinion nut, rotating the pinion occasionally to make sure cone and roller bearings are seating properly. Take frequent cone and roller bearing torque preload readings until the original recorded preload readings are obtained by rotating the pinion with a Nm (inch lbs) torque wrench. - If the original recorded preload is lower than specification (original bearings 0.8-1.5 Nm [8-14 inch lbs], new bearings 1.8-3.3 Nm [16-29 inch lbs]), tighten to specification. If the preload is higher than specification, tighten to original reading as recorded. 6. Remove the Companion Flange Holding Tool. 7. Position the rear driveshaft and align the marks on the rear axle companion flange. 8. Install the four driveshaft bolts. 9. Install the rear disc brake rotors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Companion Flange > Component Information > Service and Repair > Page 6878 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Customer Interest for Drive/Propeller Shaft: > 98-25-21 > Dec > 98 > Exhaust System - Cracks/Breaks Between Muffler/Tailpipe Drive/Propeller Shaft: Customer Interest Exhaust System - Cracks/Breaks Between Muffler/Tailpipe Article No. 98-25-21 12/21/98 EXHAUST SYSTEM - CRACK OR BREAK BETWEEN MUFFLER AND TAILPIPE - VEHICLES WITH 5.4L ENGINE AND 4X4, OR VEHICLES WITH 4.6L ENGINE AND NON-AIR SUSPENSION LIGHT TRUCK: 1997-99 EXPEDITION ISSUE Breakage of the exhaust system between the muffler and tailpipe may occur on some vehicles. This may be due to the double cardan driveshaft mass causing a resonant frequency that fatigues the exhaust system between the muffler and tailpipe. ACTION Replace the double cardan driveshaft with a new heavy duty single cardan driveshaft. Then replace broken exhaust system. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Replace the double cardan driveshaft with a new Heavy Duty Single Cardan Driveshaft (XL1Z-4602-AA - 5.4L engine or XL1Z-4602-BA - 4.6L engine) by referring to the appropriate year Expedition Workshop Manual, Section 205-01. Be sure to align paint mark on driveshaft to paint mark on axle flange. This is necessary to avoid driveline vibration. 2. Replace the muffler and tailpipe assembly by referring to the Workshop Manual, Section 309-00. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982521A Replace Driveshaft, 0.7 Hr. Muffler, And Tailpipe DEALER CODING CONDITION BASIC PART NO. CODE 4602 D9 OASIS CODES: 403000, 702000, 702200, 703000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Customer Interest for Drive/Propeller Shaft: > 98-18-7 > Sep > 98 > Steering/Driveline - High Speed Vibration Technical Service Bulletin # 98-18-7 Date: 980914 Steering/Driveline - High Speed Vibration Article No. 98-18-7 09/14/98 ^ STEERING COLUMN - HIGH SPEED VIBRATION - 4X4 VEHICLES EQUIPPED WITH COIL SUSPENSION ^ VIBRATION - HIGH SPEED VIBRATION - 4X4 VEHICLES EQUIPPED WITH COIL SUSPENSION LIGHT TRUCK: 1997-98 EXPEDITION 1998 NAVIGATOR This TSB article is being republished in its entirety to include the 1998 model year, revise the Service Procedure and include the latest level parts. ISSUE A vibration at highway speeds (approximately 97-113 km/h (60-70 mph)) may occur on some 4X4 vehicles with coil suspension. This vibration, present on cruise, however becomes more noticeable during coastdown. This may be caused by a driveline imbalance which produces a vibration in the seat, steering wheel, floorpan, and a rumble in the vehicle cabin. ACTION Refer to the following Service Procedure to determine the correct fix for the condition. PART NUMBER PART NAME F75Z-7H408-AA Transfer Case Output Plug XL1Z-4602-AA Driveshaft (5.4L Vehicles) XL1Z-4602-BA Driveshaft (4.6L vehicles) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-14-15 WARRANTY STATUS: INFORMATION ONLY OASIS CODES:303000, 304000, 508000, 509000, 703000, 703300 Service Procedure 1. Drive the vehicle and verify the condition. Record all speeds, engine rpms and transmission gears that correspond to any boom, rumble or vibration that occurs. Note if the condition is cyclical, or if the condition severity changes by changing from 2H to AWD and 4H or by changing gears (3rd or OD), or the condition changes from cruise to coast and/or tip-in or tip-out. 2. Verify tire pressures are 207 kPa (30 psi) in the front tires and 241 kPa (35 psi) in the rear. If incorrect, correct tire pressure and redrive. If condition is not resolved, exchange all four tires with those of another Expedition or Navigator with same powertrain and wheel configuration which does not exhibit the condition. Redrive or properly calibrate wheel balancer and check the balance of the tires without removal of the factory weights. If tires are out of balance, rebalance and drive the vehicle. If the condition is not resolved, proceed to Step 3. 3. Both the driveshaft and the rear axle flange will have yellow paint dots. Verify that the driveshaft yellow dot and the rear axle flange yellow dot are aligned. If not aligned, rotate driveshaft at the rear axle flange so that the yellow dots are aligned and redrive. If the condition is still present, measure the driveshaft runout at both ends and in the middle. If the runout is over 0.030" at any location, replace the original double carden driveshaft with a new heavy duty single carden Driveshaft (XL1Z-4602-AA - 5.4L engine or XL1Z-4602-BA - 4.6L engine) and redrive. If the condition is still present, disconnect the driveshaft at the rear axle and measure the rear axle flange runout per the 1997 Expedition Workshop Manual, Page 205-00-25. If the flange runout is out of specification (spec is 0.011"), consult the Sterling Axle Plant Hotline at (800) FORD-AXL. Otherwise, proceed to Step 4. 4. Index the driveshaft in 90 degree increments around the rear axle flange and drive the vehicle after each reindexing. If condition is not resolved, Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Customer Interest for Drive/Propeller Shaft: > 98-18-7 > Sep > 98 > Steering/Driveline - High Speed Vibration > Page 6891 reindex the driveshaft so that the yellow dot is aligned with the yellow dot on the rear axle flange and proceed to Step 5. NOTE AFTER CONDUCTING STEPS 1-4 AND ENSURING THAT THE CONDITION IS NOT ORIGINATING FROM THE TIRES/WHEELS AND/OR DRIVESHAFT, IT IS POSSIBLE THAT THE CONDITION COULD BE ORIGINATING FROM THE TRANSFER CASE. A TRANSFER CASE CONDITION IS TYPICALLY CHARACTERIZED BY A NOTICEABLE INCREASE IN THE SEVERITY OF THE VIBRATION FROM AN ACCELERATION/COAST TO A DECELERATION DRIVE MODE. IF THE VIBRATION CONDITION BEING EXPERIENCED IS SIMILAR TO THIS VIBRATION, COMPLETE STEPS 5-7 TO IDENTIFY IF THE TRANSFER CASE IS CONTRIBUTING TO THE CONDITION. 5. Transfer case testing is as follows: a. Index the rear driveshaft in 45 degree increments at the transfer case only (maintain the same alignment with the rear axle flange) and redrive between each index. Note if the condition severity changes. This process may reach a point where the vibration is eliminated and/or reduced to an acceptable level. Does the condition disappear or change significantly? ^ If yes, return vehicle to customer. ^ If no, or customer returns unsatisfied, proceed to Step 5b. NOTE THE TRANSFER CASE REAR OUTPUT MUST BE PLUGGED SO THAT FLUID DOES NOT SPILL DURING VEHICLE OPERATION. USE PLUG F75Z-7H408-AA. b. Completely remove the rear driveshaft from the vehicle and redrive in 4H mode so that the vehicle is being driven through the front driveshaft only. Does the condition disappear or change significantly? ^ If yes, proceed to Step 6. ^ If no, proceed to Step 7. 6. If not already done in Step 3, replace the carden rear driveshaft with a heavy duty single carden driveshaft (refer to Step 3). When installing the new driveshaft, be sure to align both the driveshaft and rear axle flange yellow paint dots. Redrive vehicle in 2H at highway speeds to verify the condition has disappeared or improved significantly. If the double carden driveshaft was replaced in Step 3, or after completing Step 6, the redrive resulted in little or no improvement, proceed to Step 7. NOTE REAR DRIVESHAFT REMOVAL IS FOR TEMPORARY TEST USE ONLY AND IS NOT RECOMMENDED FOR LONG DURATIONS OF TRAVEL. WHILE DRIVING IN THIS CONDITION, NOISE AND VIBRATIONS WILL BE EXPERIENCED AT VARIOUS SPEEDS THAT MAY NOT HAVE BEEN NOTED PREVIOUSLY. THE PURPOSE OF THIS TEST IS TO DETERMINE IF THE ORIGINAL CONDITION HAS BEEN CHANGED. 7. If the vehicle was built on or before 7/15/97, call the Transfer Case Hotline at (765) 286-6234 to request a certified transfer case. Calls to the hotline will be screened to ensure that the diagnosis in this TSB article has been followed thoroughly and properly. If your vehicle is a good candidate for a transfer case exchange, a certified transfer case will be shipped to your dealership. Install the certified transfer case into the vehicle and redrive. If the condition is not resolved, or the vehicle was built after 7/15/97, proceed to Step 8. 8. Call the Sterling Axle Plant Hotline at (800) FORD-AXL for a certified rear axle. If new axle does not completely correct the concern, repeat Step 4 and index the shaft to the axle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: > 98-25-21 > Dec > 98 > Exhaust System - Cracks/Breaks Between Muffler/Tailpipe Drive/Propeller Shaft: All Technical Service Bulletins Exhaust System - Cracks/Breaks Between Muffler/Tailpipe Article No. 98-25-21 12/21/98 EXHAUST SYSTEM - CRACK OR BREAK BETWEEN MUFFLER AND TAILPIPE - VEHICLES WITH 5.4L ENGINE AND 4X4, OR VEHICLES WITH 4.6L ENGINE AND NON-AIR SUSPENSION LIGHT TRUCK: 1997-99 EXPEDITION ISSUE Breakage of the exhaust system between the muffler and tailpipe may occur on some vehicles. This may be due to the double cardan driveshaft mass causing a resonant frequency that fatigues the exhaust system between the muffler and tailpipe. ACTION Replace the double cardan driveshaft with a new heavy duty single cardan driveshaft. Then replace broken exhaust system. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Replace the double cardan driveshaft with a new Heavy Duty Single Cardan Driveshaft (XL1Z-4602-AA - 5.4L engine or XL1Z-4602-BA - 4.6L engine) by referring to the appropriate year Expedition Workshop Manual, Section 205-01. Be sure to align paint mark on driveshaft to paint mark on axle flange. This is necessary to avoid driveline vibration. 2. Replace the muffler and tailpipe assembly by referring to the Workshop Manual, Section 309-00. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982521A Replace Driveshaft, 0.7 Hr. Muffler, And Tailpipe DEALER CODING CONDITION BASIC PART NO. CODE 4602 D9 OASIS CODES: 403000, 702000, 702200, 703000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: > 98-18-7 > Sep > 98 > Steering/Driveline - High Speed Vibration Technical Service Bulletin # 98-18-7 Date: 980914 Steering/Driveline - High Speed Vibration Article No. 98-18-7 09/14/98 ^ STEERING COLUMN - HIGH SPEED VIBRATION - 4X4 VEHICLES EQUIPPED WITH COIL SUSPENSION ^ VIBRATION - HIGH SPEED VIBRATION - 4X4 VEHICLES EQUIPPED WITH COIL SUSPENSION LIGHT TRUCK: 1997-98 EXPEDITION 1998 NAVIGATOR This TSB article is being republished in its entirety to include the 1998 model year, revise the Service Procedure and include the latest level parts. ISSUE A vibration at highway speeds (approximately 97-113 km/h (60-70 mph)) may occur on some 4X4 vehicles with coil suspension. This vibration, present on cruise, however becomes more noticeable during coastdown. This may be caused by a driveline imbalance which produces a vibration in the seat, steering wheel, floorpan, and a rumble in the vehicle cabin. ACTION Refer to the following Service Procedure to determine the correct fix for the condition. PART NUMBER PART NAME F75Z-7H408-AA Transfer Case Output Plug XL1Z-4602-AA Driveshaft (5.4L Vehicles) XL1Z-4602-BA Driveshaft (4.6L vehicles) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-14-15 WARRANTY STATUS: INFORMATION ONLY OASIS CODES:303000, 304000, 508000, 509000, 703000, 703300 Service Procedure 1. Drive the vehicle and verify the condition. Record all speeds, engine rpms and transmission gears that correspond to any boom, rumble or vibration that occurs. Note if the condition is cyclical, or if the condition severity changes by changing from 2H to AWD and 4H or by changing gears (3rd or OD), or the condition changes from cruise to coast and/or tip-in or tip-out. 2. Verify tire pressures are 207 kPa (30 psi) in the front tires and 241 kPa (35 psi) in the rear. If incorrect, correct tire pressure and redrive. If condition is not resolved, exchange all four tires with those of another Expedition or Navigator with same powertrain and wheel configuration which does not exhibit the condition. Redrive or properly calibrate wheel balancer and check the balance of the tires without removal of the factory weights. If tires are out of balance, rebalance and drive the vehicle. If the condition is not resolved, proceed to Step 3. 3. Both the driveshaft and the rear axle flange will have yellow paint dots. Verify that the driveshaft yellow dot and the rear axle flange yellow dot are aligned. If not aligned, rotate driveshaft at the rear axle flange so that the yellow dots are aligned and redrive. If the condition is still present, measure the driveshaft runout at both ends and in the middle. If the runout is over 0.030" at any location, replace the original double carden driveshaft with a new heavy duty single carden Driveshaft (XL1Z-4602-AA - 5.4L engine or XL1Z-4602-BA - 4.6L engine) and redrive. If the condition is still present, disconnect the driveshaft at the rear axle and measure the rear axle flange runout per the 1997 Expedition Workshop Manual, Page 205-00-25. If the flange runout is out of specification (spec is 0.011"), consult the Sterling Axle Plant Hotline at (800) FORD-AXL. Otherwise, proceed to Step 4. 4. Index the driveshaft in 90 degree increments around the rear axle flange and drive the vehicle after each reindexing. If condition is not resolved, Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: > 98-18-7 > Sep > 98 > Steering/Driveline - High Speed Vibration > Page 6901 reindex the driveshaft so that the yellow dot is aligned with the yellow dot on the rear axle flange and proceed to Step 5. NOTE AFTER CONDUCTING STEPS 1-4 AND ENSURING THAT THE CONDITION IS NOT ORIGINATING FROM THE TIRES/WHEELS AND/OR DRIVESHAFT, IT IS POSSIBLE THAT THE CONDITION COULD BE ORIGINATING FROM THE TRANSFER CASE. A TRANSFER CASE CONDITION IS TYPICALLY CHARACTERIZED BY A NOTICEABLE INCREASE IN THE SEVERITY OF THE VIBRATION FROM AN ACCELERATION/COAST TO A DECELERATION DRIVE MODE. IF THE VIBRATION CONDITION BEING EXPERIENCED IS SIMILAR TO THIS VIBRATION, COMPLETE STEPS 5-7 TO IDENTIFY IF THE TRANSFER CASE IS CONTRIBUTING TO THE CONDITION. 5. Transfer case testing is as follows: a. Index the rear driveshaft in 45 degree increments at the transfer case only (maintain the same alignment with the rear axle flange) and redrive between each index. Note if the condition severity changes. This process may reach a point where the vibration is eliminated and/or reduced to an acceptable level. Does the condition disappear or change significantly? ^ If yes, return vehicle to customer. ^ If no, or customer returns unsatisfied, proceed to Step 5b. NOTE THE TRANSFER CASE REAR OUTPUT MUST BE PLUGGED SO THAT FLUID DOES NOT SPILL DURING VEHICLE OPERATION. USE PLUG F75Z-7H408-AA. b. Completely remove the rear driveshaft from the vehicle and redrive in 4H mode so that the vehicle is being driven through the front driveshaft only. Does the condition disappear or change significantly? ^ If yes, proceed to Step 6. ^ If no, proceed to Step 7. 6. If not already done in Step 3, replace the carden rear driveshaft with a heavy duty single carden driveshaft (refer to Step 3). When installing the new driveshaft, be sure to align both the driveshaft and rear axle flange yellow paint dots. Redrive vehicle in 2H at highway speeds to verify the condition has disappeared or improved significantly. If the double carden driveshaft was replaced in Step 3, or after completing Step 6, the redrive resulted in little or no improvement, proceed to Step 7. NOTE REAR DRIVESHAFT REMOVAL IS FOR TEMPORARY TEST USE ONLY AND IS NOT RECOMMENDED FOR LONG DURATIONS OF TRAVEL. WHILE DRIVING IN THIS CONDITION, NOISE AND VIBRATIONS WILL BE EXPERIENCED AT VARIOUS SPEEDS THAT MAY NOT HAVE BEEN NOTED PREVIOUSLY. THE PURPOSE OF THIS TEST IS TO DETERMINE IF THE ORIGINAL CONDITION HAS BEEN CHANGED. 7. If the vehicle was built on or before 7/15/97, call the Transfer Case Hotline at (765) 286-6234 to request a certified transfer case. Calls to the hotline will be screened to ensure that the diagnosis in this TSB article has been followed thoroughly and properly. If your vehicle is a good candidate for a transfer case exchange, a certified transfer case will be shipped to your dealership. Install the certified transfer case into the vehicle and redrive. If the condition is not resolved, or the vehicle was built after 7/15/97, proceed to Step 8. 8. Call the Sterling Axle Plant Hotline at (800) FORD-AXL for a certified rear axle. If new axle does not completely correct the concern, repeat Step 4 and index the shaft to the axle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 6902 Drive/Propeller Shaft: Specifications TORQUE SPECIFICATIONS Rear Driveshaft Bolts ........................................................................................................................... .................................... 88-119 Nm (65-87 ft. lbs.) Front Driveshaft Bolts .............................................................................................................................................................. 88-119 Nm (65-87 ft. lbs.) Front Driveshaft Shield Nuts ...................................................................................................................................................... 14-22 Nm (11-16 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Diagrams > Double Cardan Rear Driveshaft - Without Air Suspension Drive/Propeller Shaft: Diagrams Double Cardan Rear Driveshaft - Without Air Suspension Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Diagrams > Double Cardan Rear Driveshaft - Without Air Suspension > Page 6905 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Diagrams > Double Cardan Rear Driveshaft - Without Air Suspension > Page 6906 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Diagrams > Page 6907 Drive/Propeller Shaft: Description and Operation The driveshaft is a tubular shaft which transfers torque from the engine, through the transmission to the rear axle. Driveshafts differ in length, diameter, and type of slip yoke to accommodate various wheelbase and powertrain combinations. The rear driveshaft is connected to the driveshaft rear axle companion flange by a driveshaft flange yoke with four bolts. It is connected to the transfer case with a driveshaft slip yoke. NOTE: - Whenever the vehicle is raised on a hoist, inspect the slip yoke seal for damage. Replace if required. - All front driveshafts are balanced. If undercoating the vehicle, protect the driveshaft and universal joints to prevent application of any undercoating material. The front driveshaft is connected to the transfer case and the front drive axle by the driveshaft flange yoke. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Diagrams > Page 6908 Drive/Propeller Shaft: Testing and Inspection 1. Road test the vehicle to determine the critical vibration points. Note the road speed, engine RPM, and shift lever positions at which the vibration occurs. 2. Stop the vehicle, place the transmission lever in neutral and run the engine through the critical speed ranges determined in Step 1. 3. If no vibration is felt, balance the driveshaft. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Drive/Propeller Shaft: Service and Repair Front REMOVAL 1. With the vehicle in neutral, raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Remove the front driveshaft shield. (1) Remove the front driveshaft shield nuts. (2) Remove the front driveshaft shield. 3. Index the front driveshaft. - Repeat it on the transfer case companion flange to front driveshaft flange yoke. 4. Remove the front driveshaft. (1) Remove the four driveshaft slip yoke to transfer case bolts. (2) Carefully remove the front driveshaft. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front > Page 6911 5. Separate the front driveshaft from the transfer case. (1) Remove the driveshaft flange yoke to front drive axle companion flange bolts. (2) Carefully remove the front driveshaft. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front > Page 6912 Drive/Propeller Shaft: Service and Repair Rear REMOVAL 1. With the vehicle in neutral, raise and support the vehicle companion flange. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Index the driveshaft to driveshaft rear axle companion flange. 3. Remove the driveshaft. (1) Remove the four driveshaft to driveshaft rear axle companion flange bolts and disconnect the driveshaft. (2) Lower the driveshaft and slide the driveshaft rearward off the transmission output shaft to remove the driveshaft. Plug the extension housing to prevent fluid loss. INSTALLATION 1. To install, reverse the removal procedure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > Customer Interest for Slip Yoke: > 97-13-21 > Jun > 97 > Driveline Clunking or Grunting Noise Slip Yoke: Customer Interest Driveline - Clunking or Grunting Noise Article No. 97-13-21 06/23/97 ^ NOISE - "CLUNKING" OR "GRUNTING" FROM DRIVELINE DURING ACCELERATION OR BRAKING - 4X4 VEHICLES BUILT THROUGH 5/15/97 ^ DRIVELINE - NOISE - "CLUNKING" OR "GRUNTING" FROM DRIVELINE DURING ACCELERATION OR BRAKING - 4X4 VEHICLES BUILT THROUGH 5/15/97 LIGHT TRUCK: 1997 EXPEDITION, F-150, F-250 This TSB article is being republished in its entirety to update the Service Procedure. ISSUE: A "clunking" or "grunting" noise may be heard from the driveline during acceleration and/or braking on some vehicles. This may be caused by the slip yoke not sliding smoothly on the transfer case output shaft splines. ACTION: Install a revised slip yoke and teflon grease to lubricate the splines. The grease should allow the new slip yoke to slide smoothly on the output shaft, reducing the possibility of noise. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform the diagnostic procedure outlined in Section 100-04 of the appropriate 1997 F-150/250 or Expedition Body/Chassis Workshop Manual to verify the driveline clunk and/or grunt. 2. If the noise is verified, index the driveshaft by marking the driveshaft yoke to axle flange to ensure initial driveshaft balance when reinstalled. Then remove the driveshaft from the vehicle. Refer to Page 205-01-07 of the Workshop Manual for the proper removal procedure. 3. Carefully remove the ground wire from the main bulkhead connector and clip. Remove the plastic wire protector shield. Remove the transfer case extension housing bolts. Remove the transfer case extension housing using caution not to damage the ground wire or pull the ground wire out of the transfer case. Remove the spillage seal from the transfer case output shaft (Figure 1). 4. Reinstall the transfer case extension housing and torque the bolts to 22-27 N.m (16-20 lb-ft). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > Customer Interest for Slip Yoke: > 97-13-21 > Jun > 97 > Driveline Clunking or Grunting Noise > Page 6921 5. Remove the slip yoke from the driveshaft and install a revised slip yoke. Refer to the Workshop Manual, Page 205-01-09 for Expedition and 205-01-17 for F-Series, for the proper procedure. Refer to the Slip Yoke Usage Chart to determine the correct part. 6. Spread 7-13 grams (0.25-0.46 oz.) of Teflon Grease (D2AZ-19590-A) evenly over the slip yoke splines. 7. Reindex and reinstall the driveshaft by inserting the slip yoke into the extension housing and tightening the axle flange bolts to 88-119 N.m (65-88 lb-ft). Be sure to align the marks on the driveshaft that were previously installed in Step 2. 8. Drain and refill the transfer case using Motorcraft MERCON(R) Multi-Purpose Automatic Transmission Fluid (ATF) (XT-2-QDX) per the Service Manual specifications. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-12-12 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971321A Replace Slip Yoke And 1.3 Hrs. Remove Spillage Seal From Transfer Case DEALER CODING CONDITION BASIC PART NO. CODE 4841 41 OASIS CODES: 597997, 702000, 702200, 702300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Slip Yoke: > 97-13-21 > Jun > 97 > Driveline - Clunking or Grunting Noise Slip Yoke: All Technical Service Bulletins Driveline - Clunking or Grunting Noise Article No. 97-13-21 06/23/97 ^ NOISE - "CLUNKING" OR "GRUNTING" FROM DRIVELINE DURING ACCELERATION OR BRAKING - 4X4 VEHICLES BUILT THROUGH 5/15/97 ^ DRIVELINE - NOISE - "CLUNKING" OR "GRUNTING" FROM DRIVELINE DURING ACCELERATION OR BRAKING - 4X4 VEHICLES BUILT THROUGH 5/15/97 LIGHT TRUCK: 1997 EXPEDITION, F-150, F-250 This TSB article is being republished in its entirety to update the Service Procedure. ISSUE: A "clunking" or "grunting" noise may be heard from the driveline during acceleration and/or braking on some vehicles. This may be caused by the slip yoke not sliding smoothly on the transfer case output shaft splines. ACTION: Install a revised slip yoke and teflon grease to lubricate the splines. The grease should allow the new slip yoke to slide smoothly on the output shaft, reducing the possibility of noise. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform the diagnostic procedure outlined in Section 100-04 of the appropriate 1997 F-150/250 or Expedition Body/Chassis Workshop Manual to verify the driveline clunk and/or grunt. 2. If the noise is verified, index the driveshaft by marking the driveshaft yoke to axle flange to ensure initial driveshaft balance when reinstalled. Then remove the driveshaft from the vehicle. Refer to Page 205-01-07 of the Workshop Manual for the proper removal procedure. 3. Carefully remove the ground wire from the main bulkhead connector and clip. Remove the plastic wire protector shield. Remove the transfer case extension housing bolts. Remove the transfer case extension housing using caution not to damage the ground wire or pull the ground wire out of the transfer case. Remove the spillage seal from the transfer case output shaft (Figure 1). 4. Reinstall the transfer case extension housing and torque the bolts to 22-27 N.m (16-20 lb-ft). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Slip Yoke: > 97-13-21 > Jun > 97 > Driveline - Clunking or Grunting Noise > Page 6927 5. Remove the slip yoke from the driveshaft and install a revised slip yoke. Refer to the Workshop Manual, Page 205-01-09 for Expedition and 205-01-17 for F-Series, for the proper procedure. Refer to the Slip Yoke Usage Chart to determine the correct part. 6. Spread 7-13 grams (0.25-0.46 oz.) of Teflon Grease (D2AZ-19590-A) evenly over the slip yoke splines. 7. Reindex and reinstall the driveshaft by inserting the slip yoke into the extension housing and tightening the axle flange bolts to 88-119 N.m (65-88 lb-ft). Be sure to align the marks on the driveshaft that were previously installed in Step 2. 8. Drain and refill the transfer case using Motorcraft MERCON(R) Multi-Purpose Automatic Transmission Fluid (ATF) (XT-2-QDX) per the Service Manual specifications. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-12-12 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971321A Replace Slip Yoke And 1.3 Hrs. Remove Spillage Seal From Transfer Case DEALER CODING CONDITION BASIC PART NO. CODE 4841 41 OASIS CODES: 597997, 702000, 702200, 702300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Universal Joint - Greasable Design Availability Universal Joint: Technical Service Bulletins Universal Joint - Greasable Design Availability Article No. 97-20-15 09/29/97 ^ DRIVESHAFT - U-JOINT - AVAILABILITY OF GREASEABLE SERVICE PARTS ^ DRIVESHAFT - U-JOINT - IDENTIFICATION OF SERVICE PARTS BY MEASUREMENT ^ DRIVESHAFT - U-JOINTS - IDENTIFICATION OF SERVICE PARTS BY MEASUREMENT LIGHT TRUCK: 1990-96 BRONCO 1990-97 AEROSTAR, ECONOLINE, F SUPER DUTY, F-150-350 SERIES, RANGER 1991-97 EXPLORER 1997 EXPEDITION, MOUNTAINEER ISSUE: Available U-joints for driveshaft service are not always identifiable through model application charts. Some customers may request greaseable U-joints as a personal preference. ACTION: Refer to the following Service Information for availability of U-joint with grease fittings. SERVICE INFORMATION TO IDENTIFY U-JOINT BY MEASUREMENT: 1. Remove the old U-joint. 2. Measure U-joint using the following measuring procedure. a. Remove bearing cups. b. Remove excess grease from bottom of bearing cups and trunnions. c. Remove seals from bearing cups and trunnions. d. Reinstall bearing cups on trunnions. e. Measure as follows, permitting a tolerance of 10.005" at Dimension "G" in Figure 1 with Dimension "D" and "E" at 10.003". Outside Snap Ring Style (Figure 1) A) Measure "G" dimension and record. B) Measure "D" dimension and record. C) Measure "E" dimension and record, Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Universal Joint - Greasable Design Availability > Page 6932 3. Identify U-joint part number using reference dimensions in the Light Truck Cross Reference Chart found at the end of this TSB article. TO IDENTIFY GREASEABLE U-JOINT FOR SERVICE: For customers who demand greaseable U-joints due to their specific vehicle duty cycle, refer to Light Truck Cross Reference Chart found at the end of this TSB article. Greaseable U-joints are typically recommended only for vehicles which operate 100% of the time in a high grit environment (e.g., coal mines). NOTE: GREASEABLE U-JOINTS DO NOT CONTAIN END PLAY THRUST WASHERS AND MAY CAUSE NOISE/VIBRATION/HARSHNESS (NVH) CONCERNS ON CERTAIN APPLICATIONS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 509000, 590000, 597997 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 6933 Universal Joint: Specifications TORQUE SPECIFICATIONS Driveshaft Flange Yoke to Transfer Case Companion Flange Bolts ............................................................................................................................. 95-129 Nm (70-95 ft. lbs.) Driveshaft Slip Yoke to Front Axle Companion Flange Bolts .................................................................................................................................. 95-129 Nm (70-95 ft. lbs.) Driveshaft Flange Yoke to Rear Axle Companion Flange Bolts ................................................................................................................................... 95-129 Nm (70-95 ft. lbs.) Front Driveshaft Shield Nuts ...................................................................................................................................................... 22-27 Nm (16-20 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 6934 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 6935 Universal Joint: Description and Operation The universal joints (U-joints) connect to each end of the driveshaft and allow for up and down movement of the axles and transmission or transfer case. The U joints are lubricated for the life of the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Universal Joint: Initial Inspection and Diagnostic Overview WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. Prior to checking driveline angularity, inspect the U joints for proper operation. Place the vehicle on a frame hoist and rotate the driveshafts by hand. Check for rough operation or seized U-joints. Replace the U-joint if it shows signs of seizure, excessive wear, or improper seating. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6938 Universal Joint: Component Tests and General Diagnostics WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. CAUTION: This operation disturbs the pinion bearing preload. Pinion bearing preload must be reset if the pinion nut has been loosened or removed for rear axle universal joint flange reindexing or replacement. 1. Raise the vehicle on a twin-post hoist that supports the rear axle. 2. Remove the driveshaft. 3. Check the rear axle universal U-joint flange for damage. 4. Position Companion Flange Runout Gauge on the rear axle U-joint flange. 5. Install Clamp Plate on Companion Flange Runout Gauge. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6939 6. Align the holes on the clamp plate with the holes in the rear axle U joint and install the bolts. Snug the bolts evenly. 7. Use Dial Indicator/Magnetic Base to turn the Companion Flange Runout Gauge as shown to locate and mark the high spot on the rear axle U-joint flange. If the flange runout exceeds 0.25 mm (0.010 inch), remove the rear axle U-joint flange, reindex one half turn on the pinion, and reinstall. Check the runout again. If necessary, rotate the rear axle U-joint flange until an acceptable runout is obtained. If the flange runout is still more than 0.25 mm (0.010 inch), replace the rear axle U-joint flange. 8. If excessive runout is still evident after replacement of the rear axle universal joint flange, replace the ring end pinion. Repeat the above checks until the runout is within specifications. Install the driveshaft. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Disassembly and Assembly Universal Joint: Service and Repair Disassembly and Assembly Double Cardan DISASSEMBLY 1. Remove driveshaft. 2. Place the driveshaft on a suitable workbench. CAUTION: Do not clamp the driveshaft in a vise or similar holding fixture. 3. Mark the positions of the driveshaft components. NOTE: If components are not marked and installed correctly, driveline imbalance may occur. 4. Clamp U-Joint Tool in a vise. 5. Remove the eight snap rings. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Disassembly and Assembly > Page 6942 6. Remove the driveshaft slip yoke. (1) Position the driveshaft slip yoke in U-Joint Tool. (2) Press out bearing cups. (3) Remove the driveshaft slip yoke. 7. Press out the second set of bearing cups. (1) Position the driveshaft slip yoke in U-Joint Tool. (2) Press out the bearing cup. (3) Rotate the driveshaft slip yoke. (4) Press out the remaining bearing cup. 8. Remove the centering cup spring. 9. Remove the driveshaft center yoke. (1) Position the driveshaft center yoke in U-Joint Tool. (2) Press out the bearing cup. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Disassembly and Assembly > Page 6943 (3) Rotate the driveshaft center yoke. (4) Press out the remaining bearing cup. Repeat to remove the spider from the driveshaft yoke. ASSEMBLY 1. Install a new bearing cup into the driveshaft yoke. (1) Start a new bearing cup into the driveshaft yoke. (2) Position the new spider in the driveshaft yoke. (3) Position the driveshaft in U-Joint Tool. (4) Press the bearing cup below the yoke surface. Repeat for the other side of the yoke. 2. Install the driveshaft center yoke. (1) Position the driveshaft center yoke in U-Joint Tool. (2) Press in a new bearing cup. (3) Rotate the driveshaft center yoke. (4) Press in the other new bearing cup. 3. Install four new snap rings. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Disassembly and Assembly > Page 6944 4. Install a new centering cup spring. 5. Install new bearing cups into the driveshaft yokes. (1) Start a new bearing cup into the driveshaft yoke. (2) Position the new spider in the driveshaft yoke. (3) Position the driveshaft in U-Joint Tool. (4) Press the bearing cup below the yoke surface. Repeat for the other yokes. 6. Install four new snap rings. 7. Check the U-joints for freedom of movement. - If bearings are binding, strike the yoke with a plastic hammer. NOTE: Do not strike the bearings. 8. Install driveshaft. Single Cardan DISASSEMBLY 1. Remove driveshaft. 2. Place the driveshaft on a suitable workbench, being careful not to damage the tube. CAUTION: Do not clamp the driveshaft in the jaws of a vise or similar holding fixture. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Disassembly and Assembly > Page 6945 3. Mark the positions of the driveshaft components. NOTE: If components are not marked and therefore installed incorrectly, driveline imbalance may occur. 4. Clamp U-Joint Tool in a vise. 5. Remove the snap rings. 6. Remove the driveshaft slip yoke. (1) Position the driveshaft slip yoke in U-Joint Tool. (2) Press out a bearing cup. (3) Rotate the driveshaft slip yoke. (4) Press on the spider to remove the remaining bearing cup. (5) Remove the driveshaft slip yoke. NOTE: If necessary, use a pair of pliers to remove a bearing cup if it cannot be pressed out all the way. 7. Repeat step 5 to remove the remaining bearing cups, spiders and driveshaft flange yoke from the drive shaft. 8. Clean the yoke area at each end of the driveshaft. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Disassembly and Assembly > Page 6946 ASSEMBLY 1. Install the bearing cup. (1) Start a new bearing cup into the driveshaft yoke. (2) Position the new spider in the driveshaft yoke. (3) Position the (A) driveshaft in (B) U-Joint Tool. (4) Press the bearing cup below the yoke surface. 2. Remove the driveshaft from U-Joint Tool and install the snap ring. NOTE: Use the yellow snap rings supplied in the kit to assemble the universal joint (U-joint). If difficulty is encountered with the yellow snap rings, install the black snap rings. 3. Repeat steps 1 and 2 for the opposite side of the driveshaft yoke. 4. Repeat steps 1 through 3 to install the remaining new bearing cups, spider, driveshaft slip yoke, driveshaft flange yoke and snap rings. 5. Check the U-joints for freedom of movement. NOTE: Do not strike the bearings. - If binding, strike the yoke with a brass or plastic hammer. 6. If necessary, use Premium Long-Life Grease XG-1-C or-K or equivalent meeting Ford Specification ESA-M1C75-B to lubricate the U-joints. 7. Install driveshaft. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Disassembly and Assembly > Page 6947 Universal Joint: Service and Repair Indexing NOTE: - If driveshaft components are replaced and driveshaft vibration is encountered after installation, index the driveshaft. - If indexing the driveshaft does not eliminate the vibration, balance the driveshaft. 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Disconnect the driveshaft. 3. Rotate the rear axle flange. 4. Connect the driveshaft. 5. Lower the vehicle and test drive NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Disassembly and Assembly > Page 6948 Universal Joint: Service and Repair Runout and Balance 1. Loosen the lug nuts. (1) Remove center cap. (2) With the weight of the vehicle on wheels, loosen but do not remove the lug nuts. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and the wheel bearing. 2. Use a twin post axle contact hoist to raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 3. Remove the tire and wheel assembly. (1) Remove the lug nuts. (2) Remove the tire and wheel assembly. 4. Install the lug nuts to retain the brake rotors. 5. Note and record the baseline speed. With the transmission in gear, increase the vehicle speed to the maximum vibration level. Note and record the speed of this vibration period as a baseline speed. CAUTION: To prevent overheating, do not run the vehicle on the hoist for an extended period. 6. Check the attachment of the driveshaft to the rear axle flange. Replace any worn parts. 7. Check the driveshaft for out of balance. (1) With the transmission in gear, run the vehicle with the speedometer indicating 64-80 km (40-50 mph). (2) Have an assistant barely contact the driveshaft with a marker in the rear, middle, and front ends to indicate heavy spots. WARNING: KEEP HANDS AWAY FROM THE BALANCE WEIGHTS WHILE THE DRIVESHAFT IS ROTATING. 8. Balance the driveshaft. (1) Install two stainless steel screw-type hose clamps on the driveshaft with the clamp screws opposite the mark. (2) Tighten the hose clamps starting at the pinion yoke end of the driveshaft. 9. Run the vehicle at the 64-80 km (40-50 mph). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Disassembly and Assembly > Page 6949 10. If the vibration is still evident, rotate the clamps away from each other until balanced and test. 11. If necessary, continue to rotate the clamps apart in smaller increments and test. If the vibration still exists, repeat the procedure at the front of the drive shaft. 12. Install tire and wheel assembly. (1) Position the tire and wheel assembly. (2) Install the lug nuts. (3) Lower the vehicle and tighten the lug nuts. (4) Install the center cap. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. 13. Road test the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Page 6950 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications TORQUE SPECIFICATIONS Tighten the flywheel bolts to: 73-87 Nm (54-64 ft. lbs.) NOTE: Refer to the illustration for tightening sequence. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 6954 Flex Plate: Service and Repair REMOVAL 1. Remove the transmission. 2. Remove the flywheel bolts. INSTALLATION 1. Tighten flywheel bolts in sequence shown. 2. Install the transmission. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation The transmission control switch (TCS) is a momentary contact switch. When the switch is pressed, a signal is sent to the powertrain control module (PCM) to allow automatic shifts from first through fourth gears or first through third gears only. The PCM energizes the transmission control indicator lamp (TCIL) when the switch has been pressed to cancel overdrive. The TCIL indicates overdrive cancel mode activated (lamp on) and electronic pressure control (EPC) circuit shorted (lamp flashing) or monitored sensor failure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Page 6960 Overdrive Indicator Lamp: Testing and Inspection The TCIL indicates overdrive cancel mode activated (lamp on), electronic pressure control circuit shorted or monitored sensor failure (lamp flashing). For testing procedures, Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Adjustments Shift Indicator: Adjustments 1. Remove the upper instrument panel steering column cover. 2. Place the transmission control selector lever in the OD position. - Rotate the transmission control selector lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise (a) position). 3. Hang an eight pound weight on the transmission control selector lever. 4. Center the pointer in the middle of the OD position. - Rotate the thumbwheel located on the bottom of the steering column to adjust the pointer. 5. Remove the eight pound weight. 6. Carefully move the shift control selector lever from detent to detent and compare with transmission settings. - Readjust if necessary. 7. Install the upper instrument panel steering column cover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Testing and Inspection Transmission Mode Indicator - A/T: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Testing and Inspection Four Wheel Drive Indicator Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6976 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6977 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6978 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6979 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6980 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6981 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6982 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6983 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6984 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6985 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6986 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6987 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6988 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6989 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6990 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6991 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6992 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6993 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6994 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6995 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6996 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6997 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6998 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6999 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7001 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7002 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7003 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7004 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7005 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7006 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7007 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7008 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7009 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7010 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7011 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7012 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7013 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7014 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7015 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7016 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7017 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7018 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7019 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7020 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7021 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7022 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7023 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7024 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7025 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7026 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7027 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7028 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7029 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7030 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7031 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7032 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7033 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7034 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7035 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7036 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7037 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7038 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7039 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7040 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7041 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7042 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7043 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7044 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7045 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7046 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7047 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7048 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7049 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7050 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7051 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7052 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7053 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7054 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7055 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7056 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7057 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7058 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7059 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7060 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7061 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7062 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7063 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7064 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7065 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7066 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7067 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7068 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7069 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7070 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque On Demand Relay Four Wheel Drive Selector Relay: Locations Torque On Demand Relay Instrument Panel View The Torque On Demand Relay is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque On Demand Relay > Page 7077 Four Wheel Drive Selector Relay: Locations Transfer Case Shift Relay Instrument Panel View The Transfer Case Shift Relays are located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Torque On Demand Relay Torque On Demand Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Torque On Demand Relay > Page 7080 Transfer Case Shift Relays Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > E40D Transmission Transmission Control Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > E40D Transmission > Page 7087 Transmission Control Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Page 7088 Overdrive Switch: Description and Operation The transmission control switch (TCS) is a momentary contact switch. When the switch is pressed, a signal is sent to the powertrain control module (PCM) to allow automatic shifts from first through fourth gears or first through third gears only. The PCM energizes the transmission control indicator lamp (TCIL) when the switch has been pressed to cancel overdrive. The TCIL indicates overdrive cancel mode activated (lamp on) and electronic pressure control (EPC) circuit shorted (lamp flashing) or monitored sensor failure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis Overdrive Switch: Flow of Diagnosis 1. Verify the customer concern by operating the transmission external control. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged shift lock actuator - Damaged transmission control switch - Failed fuse(s) Damaged wiring harness - Loose or corroded connections 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 7091 Overdrive Switch: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 7092 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 7093 Overdrive Switch: Pinpoint Tests Part 1 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 7094 Part 2 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 7095 Part 3 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 7096 Part 4 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 7097 Part 5 Of 5 Part 1 Of 3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 7098 Part 2 Of 3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 7099 Part 3 Of 3 Part 1 Of 4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 7100 Part 2 Of 4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 7101 Part 3 Of 4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 7102 Part 4 Of 4 Part 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 7103 Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 7104 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Page 7105 Overdrive Switch: Service and Repair REMOVAL 1. Remove the transmission control switch (TCS). (1) Remove the TCS cover. (2) Remove the TCS. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Description and Operation Shift Interlock Switch: Description and Operation The brake shift interlock actuator prevents moving the shift lever out of the PARK position unless the brake pedal is depressed. The actuator receives a signal from the brake on/off (BOO) switch that allows movement of the shift lever. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > New Digital Transmission Range Sensor - Service Tip Transmission Position Switch/Sensor: Technical Service Bulletins New Digital Transmission Range Sensor - Service Tip Article No. 96-24-10 11/18/96 TRANSMISSION - E40D - 4R70W - 4R44E - 5R55E - NEW DIGITAL TRANSMISSION RANGE SENSOR - DIAGNOSIS SERVICE TIP LINCOLN-MERCURY: 1997 MARK VIII LIGHT TRUCK: 1997 AEROSTAR, ECONOLINE, EXPEDITION, EXPLORER, F-150, F-250, MOUNTAINEER ISSUE: Beginning with Job 1 1997, some vehicles will be equipped with a new Digital Transmission Range (DTR) sensor. The DTR sensor is located on the outside of the transmission (Figure 1) at the outer manual lever. ACTION: Refer to the following text to properly diagnose a concern with the DTR sensor. The new DTR sensor completes the start circuit in "Park" and "Neutral," the backup lamp circuit in "Reverse" and the neutral sense circuit (4X4 only) in "Neutral." The DTR sensor also opens/closes a set of four (4) switches that are monitored by the Powertrain Control Module (PCM) to determine the position of the transmission manual lever. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > New Digital Transmission Range Sensor - Service Tip > Page 7113 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > New Digital Transmission Range Sensor - Service Tip > Page 7114 To properly diagnose the DTR sensor, use the NGS, Rotunda Transmission Tester with TR/MLP Cable "E" (Figure 2) and the new DTR Sensor Overlay (Figure 4), while following the procedures outlined in the appropriate model 1997 Service Manual, Section 07-01 or appropriate model 1997 Workshop Manual, Section 307-01. The new DTR Sensor Overlay (007-00131) and updated Tester Manual was sent to all dealers in August 1996. The TR/MLP Cable "E" (007-00111) was sent to all dealers in June 1995 (refer to TSB 95-19-7). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > New Digital Transmission Range Sensor - Service Tip > Page 7115 When using Cable "E" (Figure 3) to diagnose the DTR sensor, the slide switch must be in the "Digital" position and the "Black" 12-pin connector installed on the sensor. Having the slide switch in the incorrect position or using the incorrect 12-pin connector will result in misdiagnosis and possible replacement of a good component. For diagnosis of the DTR sensor, always refer to the appropriate model 1997 Service Manual, Section 07.01 or appropriate model 1997 Workshop Manual, Section 3O7-01 for proper procedure and required equipment. OTHER APPLICABLE ARTICLES: 95-19-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 503000, 503300, 504000, 601300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 7116 Transmission Position Switch/Sensor: Specifications TORQUE SPECIFICATIONS DTR Sensor Bolts ................................................................................................................................ ..................................... 7-10 Nm (62-89 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 7117 Transmission Position Switch/Sensor: Locations Transmission View The Digital Transmission Range Sensor is located at left side of the automatic transmission. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 7118 Digital Transmission Range Sensor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 7119 Transmission Position Switch/Sensor: Adjustments NOTE: Use Digital Transmission Range (DTR) Sensor Alignment Tool to align both TR and DTR sensors. 1. Raise and support vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Disconnect the manual lever shift control cable. 3. Disconnect the TR or DTR electrical connector. 4. Remove the manual control lever. (1) Remove the nut. (2) Remove the lever. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. 5. Loosen the TR or DTR bolts. 6. Use DTR sensor alignment tool, to align the DTR or TR sensor slots. NOTE: Manual shift lever must be in the neutral position. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 7120 7. Tighten the DTR or TR sensor bolts. 8. Install the manual control lever. (1) Position the manual control lever. (2) Install a new manual lever shaft outer nut. 9. With the manual lever in overdrive connect the shift lever control cable. 10. Install the DTR sensor electrical connector. 11. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications TORQUE SPECIFICATIONS Output Shaft Speed (OSS) Sensor Bolt .......................................................................................................................................... 8-16 Nm (6-12 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 7124 Transmission Speed Sensor: Locations Transmission View The Output Shaft Speed Sensor is located at left side of transmission. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 7125 Output Shaft Speed Sensor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Selector Switch: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions Four Wheel Drive Selector Switch: Customer Interest Transfer Case - Multiple Electrical Malfunctions Article No. 01-16-6 08/20/01 ^ LAMP - 4X4 "LOW RANGE" LIGHT DIMLY LIT ^ SWITCHES - TRANSFER CASE MODE SWITCH - 4X4 HI/LOW SWITCH SHORTED OUT ^ WINDSHIELD WIPERS - INTERMITTENT WIPERS ERRATIC OR INOPERABLE ^ TRANSFER CASE - WATER PRESENT IN TRANSFER CASE FORD: 1997 EXPEDITION, F-150, F-250 LD This article is being republished in its entirety to update the labor time. ISSUE Water may be present in the transfer case on some vehicles. This may cause: ^ Transfer Case Mode Switch to become inoperative ^ The 4X4 "Low Range" light to appear dimly lit ^ The intermittent wipers to become erratic or inoperative ^ Vehicle Speed Sensor (VSS) Diagnostic Trouble Codes (DTCs) P0500, P0503, P1500, and P1501 to be set. This may be caused by water splashing into the transfer case through the vent tube assembly, possibly causing the transfer case mode switch to short out, and/or the VSS gear to swell and set the VSS DTCs listed above. Shorting out the transfer case mode switch may cause the intermittent wiper mode to function erratically, as well as possibly causing the 4X4 light to work incorrectly. ACTION Inspect, diagnose, and/or replace the necessary components. Refer to the following Service Procedure for details. SERVICE PROCEDURE Procedure for VSS Gear: 1. Inspect VSS gear in the transfer case for looseness. 2. Replace Gear (C80Z-17285-B) as necessary. Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Mode Switch: 1. Check resistance of the Transfer Case Mode Switch. 2. The resistance of the switch should be at least 100,000 ohms. If it is less, replace the switch (3-Position Switch, E7TZ-7E440-A, manual shift only). Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Vent Replacement: 1. Remove old vent hose from fitting on front of transfer case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Selector Switch: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 7135 2. Attach end of new Vent Hose (F75Z-7A246-M) to fitting, and route the hose up over the top of the transfer case (Figure 1). 3. Attach the clip on the vent hose to the top of the vertical rib on the transfer case extension housing to support the end of the hose (Figure 2). NOTE FOR ALL WATER CONCERNS, DRAIN AND REFILL THE TRANSFER CASE WITH FRESH FLUID (XT-2-QDX), AND REPLACE THE VENT HOSE WITH THE REVISED PART. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Selector Switch: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 7136 SUPERSEDES:97-11-19 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011606A Drain And Refill Transfer 1.2 Hrs. Case, Inspect And/Or Replace VSS Gear And Transfer Case Mode Switch, And Install Vent Kit DEALER CODING CONDITION BASIC PART NO. CODE 7D494 49 OASIS CODES: 202000, 206000, 508000, 508300, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Selector Switch: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions Four Wheel Drive Selector Switch: All Technical Service Bulletins Transfer Case - Multiple Electrical Malfunctions Article No. 01-16-6 08/20/01 ^ LAMP - 4X4 "LOW RANGE" LIGHT DIMLY LIT ^ SWITCHES - TRANSFER CASE MODE SWITCH - 4X4 HI/LOW SWITCH SHORTED OUT ^ WINDSHIELD WIPERS - INTERMITTENT WIPERS ERRATIC OR INOPERABLE ^ TRANSFER CASE - WATER PRESENT IN TRANSFER CASE FORD: 1997 EXPEDITION, F-150, F-250 LD This article is being republished in its entirety to update the labor time. ISSUE Water may be present in the transfer case on some vehicles. This may cause: ^ Transfer Case Mode Switch to become inoperative ^ The 4X4 "Low Range" light to appear dimly lit ^ The intermittent wipers to become erratic or inoperative ^ Vehicle Speed Sensor (VSS) Diagnostic Trouble Codes (DTCs) P0500, P0503, P1500, and P1501 to be set. This may be caused by water splashing into the transfer case through the vent tube assembly, possibly causing the transfer case mode switch to short out, and/or the VSS gear to swell and set the VSS DTCs listed above. Shorting out the transfer case mode switch may cause the intermittent wiper mode to function erratically, as well as possibly causing the 4X4 light to work incorrectly. ACTION Inspect, diagnose, and/or replace the necessary components. Refer to the following Service Procedure for details. SERVICE PROCEDURE Procedure for VSS Gear: 1. Inspect VSS gear in the transfer case for looseness. 2. Replace Gear (C80Z-17285-B) as necessary. Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Mode Switch: 1. Check resistance of the Transfer Case Mode Switch. 2. The resistance of the switch should be at least 100,000 ohms. If it is less, replace the switch (3-Position Switch, E7TZ-7E440-A, manual shift only). Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Vent Replacement: 1. Remove old vent hose from fitting on front of transfer case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Selector Switch: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 7142 2. Attach end of new Vent Hose (F75Z-7A246-M) to fitting, and route the hose up over the top of the transfer case (Figure 1). 3. Attach the clip on the vent hose to the top of the vertical rib on the transfer case extension housing to support the end of the hose (Figure 2). NOTE FOR ALL WATER CONCERNS, DRAIN AND REFILL THE TRANSFER CASE WITH FRESH FLUID (XT-2-QDX), AND REPLACE THE VENT HOSE WITH THE REVISED PART. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Selector Switch: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 7143 SUPERSEDES:97-11-19 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011606A Drain And Refill Transfer 1.2 Hrs. Case, Inspect And/Or Replace VSS Gear And Transfer Case Mode Switch, And Install Vent Kit DEALER CODING CONDITION BASIC PART NO. CODE 7D494 49 OASIS CODES: 202000, 206000, 508000, 508300, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Page 7144 Four Wheel Drive Selector Switch: Specifications TORQUE SPECIFICATIONS Shift Range Selector Switch Screws ........................................................................................................................................... 2-3 Nm (18-26 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Page 7145 4 Wheel Drive Mode Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Page 7146 Four Wheel Drive Selector Switch: Description and Operation The 4WD mode switch is a rotary switch which allows the vehicle operator to choose between 2WD, A4WD, 4WD HIGH, and LOW range positions. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Page 7147 Four Wheel Drive Selector Switch: Service and Repair REMOVAL 1. Remove the center instrument panel trim plate. 2. Remove the shift range selector switch. (1) Remove the shift range selector switch knob. (2) Disconnect the shift range selector switch electrical connector. (3) Remove the two shift range selector switch screws. (4) Remove the shift range selector switch. INSTALLATION 1. Install the shift range selector switch. (1) Position the shift range selector switch. (2) Install the bolts. (3) Install the electrical connectors. (4) Install the knob. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Page 7148 2. Install the center instrument panel trim panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Speed Sensor: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions Speed Sensor: Customer Interest Transfer Case - Multiple Electrical Malfunctions Article No. 01-16-6 08/20/01 ^ LAMP - 4X4 "LOW RANGE" LIGHT DIMLY LIT ^ SWITCHES - TRANSFER CASE MODE SWITCH - 4X4 HI/LOW SWITCH SHORTED OUT ^ WINDSHIELD WIPERS - INTERMITTENT WIPERS ERRATIC OR INOPERABLE ^ TRANSFER CASE - WATER PRESENT IN TRANSFER CASE FORD: 1997 EXPEDITION, F-150, F-250 LD This article is being republished in its entirety to update the labor time. ISSUE Water may be present in the transfer case on some vehicles. This may cause: ^ Transfer Case Mode Switch to become inoperative ^ The 4X4 "Low Range" light to appear dimly lit ^ The intermittent wipers to become erratic or inoperative ^ Vehicle Speed Sensor (VSS) Diagnostic Trouble Codes (DTCs) P0500, P0503, P1500, and P1501 to be set. This may be caused by water splashing into the transfer case through the vent tube assembly, possibly causing the transfer case mode switch to short out, and/or the VSS gear to swell and set the VSS DTCs listed above. Shorting out the transfer case mode switch may cause the intermittent wiper mode to function erratically, as well as possibly causing the 4X4 light to work incorrectly. ACTION Inspect, diagnose, and/or replace the necessary components. Refer to the following Service Procedure for details. SERVICE PROCEDURE Procedure for VSS Gear: 1. Inspect VSS gear in the transfer case for looseness. 2. Replace Gear (C80Z-17285-B) as necessary. Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Mode Switch: 1. Check resistance of the Transfer Case Mode Switch. 2. The resistance of the switch should be at least 100,000 ohms. If it is less, replace the switch (3-Position Switch, E7TZ-7E440-A, manual shift only). Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Vent Replacement: 1. Remove old vent hose from fitting on front of transfer case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Speed Sensor: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 7157 2. Attach end of new Vent Hose (F75Z-7A246-M) to fitting, and route the hose up over the top of the transfer case (Figure 1). 3. Attach the clip on the vent hose to the top of the vertical rib on the transfer case extension housing to support the end of the hose (Figure 2). NOTE FOR ALL WATER CONCERNS, DRAIN AND REFILL THE TRANSFER CASE WITH FRESH FLUID (XT-2-QDX), AND REPLACE THE VENT HOSE WITH THE REVISED PART. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Speed Sensor: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 7158 SUPERSEDES:97-11-19 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011606A Drain And Refill Transfer 1.2 Hrs. Case, Inspect And/Or Replace VSS Gear And Transfer Case Mode Switch, And Install Vent Kit DEALER CODING CONDITION BASIC PART NO. CODE 7D494 49 OASIS CODES: 202000, 206000, 508000, 508300, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions Speed Sensor: All Technical Service Bulletins Transfer Case - Multiple Electrical Malfunctions Article No. 01-16-6 08/20/01 ^ LAMP - 4X4 "LOW RANGE" LIGHT DIMLY LIT ^ SWITCHES - TRANSFER CASE MODE SWITCH - 4X4 HI/LOW SWITCH SHORTED OUT ^ WINDSHIELD WIPERS - INTERMITTENT WIPERS ERRATIC OR INOPERABLE ^ TRANSFER CASE - WATER PRESENT IN TRANSFER CASE FORD: 1997 EXPEDITION, F-150, F-250 LD This article is being republished in its entirety to update the labor time. ISSUE Water may be present in the transfer case on some vehicles. This may cause: ^ Transfer Case Mode Switch to become inoperative ^ The 4X4 "Low Range" light to appear dimly lit ^ The intermittent wipers to become erratic or inoperative ^ Vehicle Speed Sensor (VSS) Diagnostic Trouble Codes (DTCs) P0500, P0503, P1500, and P1501 to be set. This may be caused by water splashing into the transfer case through the vent tube assembly, possibly causing the transfer case mode switch to short out, and/or the VSS gear to swell and set the VSS DTCs listed above. Shorting out the transfer case mode switch may cause the intermittent wiper mode to function erratically, as well as possibly causing the 4X4 light to work incorrectly. ACTION Inspect, diagnose, and/or replace the necessary components. Refer to the following Service Procedure for details. SERVICE PROCEDURE Procedure for VSS Gear: 1. Inspect VSS gear in the transfer case for looseness. 2. Replace Gear (C80Z-17285-B) as necessary. Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Mode Switch: 1. Check resistance of the Transfer Case Mode Switch. 2. The resistance of the switch should be at least 100,000 ohms. If it is less, replace the switch (3-Position Switch, E7TZ-7E440-A, manual shift only). Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Vent Replacement: 1. Remove old vent hose from fitting on front of transfer case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 7164 2. Attach end of new Vent Hose (F75Z-7A246-M) to fitting, and route the hose up over the top of the transfer case (Figure 1). 3. Attach the clip on the vent hose to the top of the vertical rib on the transfer case extension housing to support the end of the hose (Figure 2). NOTE FOR ALL WATER CONCERNS, DRAIN AND REFILL THE TRANSFER CASE WITH FRESH FLUID (XT-2-QDX), AND REPLACE THE VENT HOSE WITH THE REVISED PART. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 7165 SUPERSEDES:97-11-19 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011606A Drain And Refill Transfer 1.2 Hrs. Case, Inspect And/Or Replace VSS Gear And Transfer Case Mode Switch, And Install Vent Kit DEALER CODING CONDITION BASIC PART NO. CODE 7D494 49 OASIS CODES: 202000, 206000, 508000, 508300, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Page 7166 Speed Sensor: Specifications TORQUE SPECIFICATIONS Output Speed Sensor Bolt ........................................................................................................................................................... 3-6 Nm (27-53 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications Transfer Case Actuator: Specifications TORQUE SPECIFICATIONS Shift Motor Bolts .................................................................................................................................. .................................... 8-11 Nm (71-98 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 7172 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 7173 Transfer Case Actuator: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 7174 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 7175 Transfer Case Actuator: Description and Operation The shifting operation of the front drive axle is accomplished by activating the vacuum motor from a switch located on the instrument panel. It is recommended that shifting of the front axle should be done with the front wheels in a straight ahead position and during light throttle application. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor Transfer Case Actuator: Service and Repair Transfer Case Shift Motor REMOVAL 1. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. Raise and support the vehicle. 2. Disconnect the shift motor electrical connector. 3. Remove the coil wire from the transfer case shift motor electrical connector. 1 Remove the wire connector spacer. 2 Remove the coil wire and pin. Use proper electrical connector pin remover. 4. Remove the transfer case shift motor. 1 Remove the four bolts. 2 Remove the transfer case shift motor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 7178 1. Install the transfer case shift motor. 1 Position the transfer case shift motor. 2 Install the four bolts. 2. Install the coil wire into the transfer case shift motor electrical connector. 1 Install the coil wire and pin. 2 Install the wire connector spacer. 3. Connect the electric shift motor electrical connector. 4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 7179 Transfer Case Actuator: Service and Repair Vacuum Reservoir REMOVAL 1. Remove the right front fender splash shield. 1 Remove the screws. 2 Remove the pushpins. 3 Remove the right front fender splash shield. 2. Remove the engine vacuum reservoir. 1 Remove the bolts. 2 Disconnect the vacuum harness from the engine vacuum reservoir and remove the engine vacuum reservoir. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 7180 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 7181 Transfer Case Actuator: Service and Repair Auxiliary Vacuum Reservoir REMOVAL 1. Remove the front fender splash shield. 2. Disconnect the vacuum harness from the auxiliary vacuum reservoir and the A/C vacuum reservoir. 3. Slide the vacuum reservoir assembly out of the battery tray. 4. Separate the A/C vacuum reservoir from the auxiliary vacuum reservoir. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Case: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions Case: Customer Interest Transfer Case - Multiple Electrical Malfunctions Article No. 01-16-6 08/20/01 ^ LAMP - 4X4 "LOW RANGE" LIGHT DIMLY LIT ^ SWITCHES - TRANSFER CASE MODE SWITCH - 4X4 HI/LOW SWITCH SHORTED OUT ^ WINDSHIELD WIPERS - INTERMITTENT WIPERS ERRATIC OR INOPERABLE ^ TRANSFER CASE - WATER PRESENT IN TRANSFER CASE FORD: 1997 EXPEDITION, F-150, F-250 LD This article is being republished in its entirety to update the labor time. ISSUE Water may be present in the transfer case on some vehicles. This may cause: ^ Transfer Case Mode Switch to become inoperative ^ The 4X4 "Low Range" light to appear dimly lit ^ The intermittent wipers to become erratic or inoperative ^ Vehicle Speed Sensor (VSS) Diagnostic Trouble Codes (DTCs) P0500, P0503, P1500, and P1501 to be set. This may be caused by water splashing into the transfer case through the vent tube assembly, possibly causing the transfer case mode switch to short out, and/or the VSS gear to swell and set the VSS DTCs listed above. Shorting out the transfer case mode switch may cause the intermittent wiper mode to function erratically, as well as possibly causing the 4X4 light to work incorrectly. ACTION Inspect, diagnose, and/or replace the necessary components. Refer to the following Service Procedure for details. SERVICE PROCEDURE Procedure for VSS Gear: 1. Inspect VSS gear in the transfer case for looseness. 2. Replace Gear (C80Z-17285-B) as necessary. Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Mode Switch: 1. Check resistance of the Transfer Case Mode Switch. 2. The resistance of the switch should be at least 100,000 ohms. If it is less, replace the switch (3-Position Switch, E7TZ-7E440-A, manual shift only). Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Vent Replacement: 1. Remove old vent hose from fitting on front of transfer case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Case: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 7190 2. Attach end of new Vent Hose (F75Z-7A246-M) to fitting, and route the hose up over the top of the transfer case (Figure 1). 3. Attach the clip on the vent hose to the top of the vertical rib on the transfer case extension housing to support the end of the hose (Figure 2). NOTE FOR ALL WATER CONCERNS, DRAIN AND REFILL THE TRANSFER CASE WITH FRESH FLUID (XT-2-QDX), AND REPLACE THE VENT HOSE WITH THE REVISED PART. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Case: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 7191 SUPERSEDES:97-11-19 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011606A Drain And Refill Transfer 1.2 Hrs. Case, Inspect And/Or Replace VSS Gear And Transfer Case Mode Switch, And Install Vent Kit DEALER CODING CONDITION BASIC PART NO. CODE 7D494 49 OASIS CODES: 202000, 206000, 508000, 508300, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions Case: All Technical Service Bulletins Transfer Case - Multiple Electrical Malfunctions Article No. 01-16-6 08/20/01 ^ LAMP - 4X4 "LOW RANGE" LIGHT DIMLY LIT ^ SWITCHES - TRANSFER CASE MODE SWITCH - 4X4 HI/LOW SWITCH SHORTED OUT ^ WINDSHIELD WIPERS - INTERMITTENT WIPERS ERRATIC OR INOPERABLE ^ TRANSFER CASE - WATER PRESENT IN TRANSFER CASE FORD: 1997 EXPEDITION, F-150, F-250 LD This article is being republished in its entirety to update the labor time. ISSUE Water may be present in the transfer case on some vehicles. This may cause: ^ Transfer Case Mode Switch to become inoperative ^ The 4X4 "Low Range" light to appear dimly lit ^ The intermittent wipers to become erratic or inoperative ^ Vehicle Speed Sensor (VSS) Diagnostic Trouble Codes (DTCs) P0500, P0503, P1500, and P1501 to be set. This may be caused by water splashing into the transfer case through the vent tube assembly, possibly causing the transfer case mode switch to short out, and/or the VSS gear to swell and set the VSS DTCs listed above. Shorting out the transfer case mode switch may cause the intermittent wiper mode to function erratically, as well as possibly causing the 4X4 light to work incorrectly. ACTION Inspect, diagnose, and/or replace the necessary components. Refer to the following Service Procedure for details. SERVICE PROCEDURE Procedure for VSS Gear: 1. Inspect VSS gear in the transfer case for looseness. 2. Replace Gear (C80Z-17285-B) as necessary. Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Mode Switch: 1. Check resistance of the Transfer Case Mode Switch. 2. The resistance of the switch should be at least 100,000 ohms. If it is less, replace the switch (3-Position Switch, E7TZ-7E440-A, manual shift only). Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Vent Replacement: 1. Remove old vent hose from fitting on front of transfer case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 7197 2. Attach end of new Vent Hose (F75Z-7A246-M) to fitting, and route the hose up over the top of the transfer case (Figure 1). 3. Attach the clip on the vent hose to the top of the vertical rib on the transfer case extension housing to support the end of the hose (Figure 2). NOTE FOR ALL WATER CONCERNS, DRAIN AND REFILL THE TRANSFER CASE WITH FRESH FLUID (XT-2-QDX), AND REPLACE THE VENT HOSE WITH THE REVISED PART. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 7198 SUPERSEDES:97-11-19 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011606A Drain And Refill Transfer 1.2 Hrs. Case, Inspect And/Or Replace VSS Gear And Transfer Case Mode Switch, And Install Vent Kit DEALER CODING CONDITION BASIC PART NO. CODE 7D494 49 OASIS CODES: 202000, 206000, 508000, 508300, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Differential, Transfer Case > Component Information > Specifications > Capacity Specifications Differential: Capacity Specifications Please refer to Transfer Case Fluid; Specifications for the fluid capacity of the Transfer Case assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Differential, Transfer Case > Component Information > Specifications > Capacity Specifications > Page 7203 Differential: Fluid Type Specifications TYPE .............................................................................................................................................................. MERCON(R) Automatic Transmission Fluid Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications Capacity (Refill) ................................................................................................................................... ................................................................... 8.2 Pints Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 7208 Fluid - Transfer Case: Fluid Type Specifications TYPE .............................................................................................................................................................. MERCON(R) Automatic Transmission Fluid Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Testing and Inspection Four Wheel Drive Indicator Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque On Demand Relay Four Wheel Drive Selector Relay: Locations Torque On Demand Relay Instrument Panel View The Torque On Demand Relay is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque On Demand Relay > Page 7216 Four Wheel Drive Selector Relay: Locations Transfer Case Shift Relay Instrument Panel View The Transfer Case Shift Relays are located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Torque On Demand Relay Torque On Demand Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Torque On Demand Relay > Page 7219 Transfer Case Shift Relays Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Selector Switch: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions Four Wheel Drive Selector Switch: Customer Interest Transfer Case - Multiple Electrical Malfunctions Article No. 01-16-6 08/20/01 ^ LAMP - 4X4 "LOW RANGE" LIGHT DIMLY LIT ^ SWITCHES - TRANSFER CASE MODE SWITCH - 4X4 HI/LOW SWITCH SHORTED OUT ^ WINDSHIELD WIPERS - INTERMITTENT WIPERS ERRATIC OR INOPERABLE ^ TRANSFER CASE - WATER PRESENT IN TRANSFER CASE FORD: 1997 EXPEDITION, F-150, F-250 LD This article is being republished in its entirety to update the labor time. ISSUE Water may be present in the transfer case on some vehicles. This may cause: ^ Transfer Case Mode Switch to become inoperative ^ The 4X4 "Low Range" light to appear dimly lit ^ The intermittent wipers to become erratic or inoperative ^ Vehicle Speed Sensor (VSS) Diagnostic Trouble Codes (DTCs) P0500, P0503, P1500, and P1501 to be set. This may be caused by water splashing into the transfer case through the vent tube assembly, possibly causing the transfer case mode switch to short out, and/or the VSS gear to swell and set the VSS DTCs listed above. Shorting out the transfer case mode switch may cause the intermittent wiper mode to function erratically, as well as possibly causing the 4X4 light to work incorrectly. ACTION Inspect, diagnose, and/or replace the necessary components. Refer to the following Service Procedure for details. SERVICE PROCEDURE Procedure for VSS Gear: 1. Inspect VSS gear in the transfer case for looseness. 2. Replace Gear (C80Z-17285-B) as necessary. Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Mode Switch: 1. Check resistance of the Transfer Case Mode Switch. 2. The resistance of the switch should be at least 100,000 ohms. If it is less, replace the switch (3-Position Switch, E7TZ-7E440-A, manual shift only). Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Vent Replacement: 1. Remove old vent hose from fitting on front of transfer case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Selector Switch: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 7228 2. Attach end of new Vent Hose (F75Z-7A246-M) to fitting, and route the hose up over the top of the transfer case (Figure 1). 3. Attach the clip on the vent hose to the top of the vertical rib on the transfer case extension housing to support the end of the hose (Figure 2). NOTE FOR ALL WATER CONCERNS, DRAIN AND REFILL THE TRANSFER CASE WITH FRESH FLUID (XT-2-QDX), AND REPLACE THE VENT HOSE WITH THE REVISED PART. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Selector Switch: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 7229 SUPERSEDES:97-11-19 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011606A Drain And Refill Transfer 1.2 Hrs. Case, Inspect And/Or Replace VSS Gear And Transfer Case Mode Switch, And Install Vent Kit DEALER CODING CONDITION BASIC PART NO. CODE 7D494 49 OASIS CODES: 202000, 206000, 508000, 508300, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Selector Switch: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions Four Wheel Drive Selector Switch: All Technical Service Bulletins Transfer Case - Multiple Electrical Malfunctions Article No. 01-16-6 08/20/01 ^ LAMP - 4X4 "LOW RANGE" LIGHT DIMLY LIT ^ SWITCHES - TRANSFER CASE MODE SWITCH - 4X4 HI/LOW SWITCH SHORTED OUT ^ WINDSHIELD WIPERS - INTERMITTENT WIPERS ERRATIC OR INOPERABLE ^ TRANSFER CASE - WATER PRESENT IN TRANSFER CASE FORD: 1997 EXPEDITION, F-150, F-250 LD This article is being republished in its entirety to update the labor time. ISSUE Water may be present in the transfer case on some vehicles. This may cause: ^ Transfer Case Mode Switch to become inoperative ^ The 4X4 "Low Range" light to appear dimly lit ^ The intermittent wipers to become erratic or inoperative ^ Vehicle Speed Sensor (VSS) Diagnostic Trouble Codes (DTCs) P0500, P0503, P1500, and P1501 to be set. This may be caused by water splashing into the transfer case through the vent tube assembly, possibly causing the transfer case mode switch to short out, and/or the VSS gear to swell and set the VSS DTCs listed above. Shorting out the transfer case mode switch may cause the intermittent wiper mode to function erratically, as well as possibly causing the 4X4 light to work incorrectly. ACTION Inspect, diagnose, and/or replace the necessary components. Refer to the following Service Procedure for details. SERVICE PROCEDURE Procedure for VSS Gear: 1. Inspect VSS gear in the transfer case for looseness. 2. Replace Gear (C80Z-17285-B) as necessary. Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Mode Switch: 1. Check resistance of the Transfer Case Mode Switch. 2. The resistance of the switch should be at least 100,000 ohms. If it is less, replace the switch (3-Position Switch, E7TZ-7E440-A, manual shift only). Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Vent Replacement: 1. Remove old vent hose from fitting on front of transfer case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Selector Switch: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 7235 2. Attach end of new Vent Hose (F75Z-7A246-M) to fitting, and route the hose up over the top of the transfer case (Figure 1). 3. Attach the clip on the vent hose to the top of the vertical rib on the transfer case extension housing to support the end of the hose (Figure 2). NOTE FOR ALL WATER CONCERNS, DRAIN AND REFILL THE TRANSFER CASE WITH FRESH FLUID (XT-2-QDX), AND REPLACE THE VENT HOSE WITH THE REVISED PART. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Selector Switch: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 7236 SUPERSEDES:97-11-19 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011606A Drain And Refill Transfer 1.2 Hrs. Case, Inspect And/Or Replace VSS Gear And Transfer Case Mode Switch, And Install Vent Kit DEALER CODING CONDITION BASIC PART NO. CODE 7D494 49 OASIS CODES: 202000, 206000, 508000, 508300, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Page 7237 Four Wheel Drive Selector Switch: Specifications TORQUE SPECIFICATIONS Shift Range Selector Switch Screws ........................................................................................................................................... 2-3 Nm (18-26 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Page 7238 4 Wheel Drive Mode Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Page 7239 Four Wheel Drive Selector Switch: Description and Operation The 4WD mode switch is a rotary switch which allows the vehicle operator to choose between 2WD, A4WD, 4WD HIGH, and LOW range positions. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Page 7240 Four Wheel Drive Selector Switch: Service and Repair REMOVAL 1. Remove the center instrument panel trim plate. 2. Remove the shift range selector switch. (1) Remove the shift range selector switch knob. (2) Disconnect the shift range selector switch electrical connector. (3) Remove the two shift range selector switch screws. (4) Remove the shift range selector switch. INSTALLATION 1. Install the shift range selector switch. (1) Position the shift range selector switch. (2) Install the bolts. (3) Install the electrical connectors. (4) Install the knob. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Page 7241 2. Install the center instrument panel trim panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Testing and Inspection Four Wheel Drive Indicator Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Output Shaft: > 98-5-8 > Mar > 98 > MIL ON/DTC P0503/Erratic Speedometer/Shifting Output Shaft: Customer Interest MIL ON/DTC P0503/Erratic Speedometer/Shifting Article No. 98-5-8 03/16/98 ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODE (DTC) P0503 STORED IN MEMORY - 4X4 VEHICLES ONLY ^ TRANSMISSION - SHIFT CONCERNS AND/OR ERRATIC SPEEDOMETER OPERATION MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - 4X4 VEHICLES ONLY LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR This TSB article is being republished in its entirety to correct the parts listed. ISSUE: The Malfunction Indicator Lamp (MIL) may illuminate and Diagnostic Trouble Code (DTC) P0503 may be stored in memory. There may also be transmission shift concerns and/or erratic speedometer operation. This may be caused by the speedometer drive gear being loose on the transfer case output shaft. ACTION: Replace the speedometer drive gear. The new gear has a tighter fit and should reduce the possibility of erratic signals. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal diagnostics as outlined in the 1997 or 1998 Powertrain Control/Emissions Diagnosis (PC/ED) On-Board Diagnostics II (OBDII) Service Manual. Service as required. 2. If no concerns were found or the concern is still present, replace the speedometer drive gear. 3. Remove the four (4) rear driveshaft flange bolts and remove the rear driveshaft. NOTE: TO MAINTAIN INITIAL DRIVESHAFT BALANCE, MARK THE REAR DRIVESHAFT YOKE AND AXLE FLANGE SO THEY CAN BE REASSEMBLED IN THEIR ORIGINAL POSITIONS. 4. Remove the six (6) extension housing bolts and remove the rear extension housing. 5. Remove the speedometer gear spacer then push the speedometer drive gear toward the transfer case and remove the steel ball. The speedometer drive gear can now be removed from the output shaft. 6. To install the revised Speedometer Drive Gear (F7TZ-17285-AA), reverse the removal procedure. NOTE: THE NEW SPEEDOMETER DRIVE GEAR WILL HAVE A SLIGHT INTERFERENCE FIT, HOWEVER IT WILL GO ON TO THE OUTPUT SHAFT BY HAND. DO NOT HEAT THE GEAR. 7. Before installing the extension housing, apply a small bead of sealant to the transfer case cover and extension housing mating surfaces. Use Ford Ultra Silicone Sealant (F7TZ-19554-AA or equivalent). 8. Top off transfer case with MERCON® (XT-2-QDX). PART NUMBER PART NAME F7IZ-19554-AA Ultra Silicone Sealant F7TZ-17285-AA Speedometer Drive Gear Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Output Shaft: > 98-5-8 > Mar > 98 > MIL ON/DTC P0503/Erratic Speedometer/Shifting > Page 7254 XT-2-QDX MERCON(R) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-3-17 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 980508A Replace Speedometer 0.8 Hr. Drive Gear DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 33 OASIS CODES: 204000, 204100, 204200, 206000, 501000, 501200, 502000, 508000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Output Shaft: > 98-5-8 > Mar > 98 > MIL ON/DTC P0503/Erratic Speedometer/Shifting Output Shaft: All Technical Service Bulletins MIL ON/DTC P0503/Erratic Speedometer/Shifting Article No. 98-5-8 03/16/98 ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODE (DTC) P0503 STORED IN MEMORY - 4X4 VEHICLES ONLY ^ TRANSMISSION - SHIFT CONCERNS AND/OR ERRATIC SPEEDOMETER OPERATION MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - 4X4 VEHICLES ONLY LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR This TSB article is being republished in its entirety to correct the parts listed. ISSUE: The Malfunction Indicator Lamp (MIL) may illuminate and Diagnostic Trouble Code (DTC) P0503 may be stored in memory. There may also be transmission shift concerns and/or erratic speedometer operation. This may be caused by the speedometer drive gear being loose on the transfer case output shaft. ACTION: Replace the speedometer drive gear. The new gear has a tighter fit and should reduce the possibility of erratic signals. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal diagnostics as outlined in the 1997 or 1998 Powertrain Control/Emissions Diagnosis (PC/ED) On-Board Diagnostics II (OBDII) Service Manual. Service as required. 2. If no concerns were found or the concern is still present, replace the speedometer drive gear. 3. Remove the four (4) rear driveshaft flange bolts and remove the rear driveshaft. NOTE: TO MAINTAIN INITIAL DRIVESHAFT BALANCE, MARK THE REAR DRIVESHAFT YOKE AND AXLE FLANGE SO THEY CAN BE REASSEMBLED IN THEIR ORIGINAL POSITIONS. 4. Remove the six (6) extension housing bolts and remove the rear extension housing. 5. Remove the speedometer gear spacer then push the speedometer drive gear toward the transfer case and remove the steel ball. The speedometer drive gear can now be removed from the output shaft. 6. To install the revised Speedometer Drive Gear (F7TZ-17285-AA), reverse the removal procedure. NOTE: THE NEW SPEEDOMETER DRIVE GEAR WILL HAVE A SLIGHT INTERFERENCE FIT, HOWEVER IT WILL GO ON TO THE OUTPUT SHAFT BY HAND. DO NOT HEAT THE GEAR. 7. Before installing the extension housing, apply a small bead of sealant to the transfer case cover and extension housing mating surfaces. Use Ford Ultra Silicone Sealant (F7TZ-19554-AA or equivalent). 8. Top off transfer case with MERCON® (XT-2-QDX). PART NUMBER PART NAME F7IZ-19554-AA Ultra Silicone Sealant F7TZ-17285-AA Speedometer Drive Gear Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Output Shaft, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Output Shaft: > 98-5-8 > Mar > 98 > MIL ON/DTC P0503/Erratic Speedometer/Shifting > Page 7260 XT-2-QDX MERCON(R) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-3-17 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 980508A Replace Speedometer 0.8 Hr. Drive Gear DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 33 OASIS CODES: 204000, 204100, 204200, 206000, 501000, 501200, 502000, 508000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque On Demand Relay Four Wheel Drive Selector Relay: Locations Torque On Demand Relay Instrument Panel View The Torque On Demand Relay is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque On Demand Relay > Page 7266 Four Wheel Drive Selector Relay: Locations Transfer Case Shift Relay Instrument Panel View The Transfer Case Shift Relays are located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Torque On Demand Relay Torque On Demand Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Torque On Demand Relay > Page 7269 Transfer Case Shift Relays Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 97-12-13 > Jun > 97 > A/T - Low Transmission Fluid/Shift/Engagement Concerns Seals and Gaskets: Customer Interest A/T - Low Transmission Fluid/Shift/Engagement Concerns Article No. 97-12-13 06/09/97 TRANSMISSION - C6, E4OD, AOD, 4R70W - LOW TRANSMISSION FLUID LEVEL AND/OR SHIFT AND/OR ENGAGEMENT CONCERNS - 4X4 AND AWD VEHICLES ONLY LIGHT TRUCK: 1987-96 BRONCO 1987-97 F-150, F-250, F-350 1996-97 EXPLORER 1997 EXPEDITION, MOUNTAINEER This TSB article is being republished in its entirety to include 1997 model year vehicles. ISSUE: The transmission may have low fluid level and/or may have either a shift concern and/or an engagement concern. This may be caused by transmission fluid leaking from the transmission into the transfer case through the transfer case input seal. ACTION: Replace the transfer case input seal. The new seal should reduce the possibility of fluid leaking from the transmission into the transfer case. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Check the transmission fluid level. It the transmission fluid level is low and there are no visible signs of a leak, check the transfer case fluid level. The level of fluid in the transfer case should be just below the fill plug hole. 2. If the transfer case fluid level is overfull and the transmission fluid is not burnt, remove the transfer case from the vehicle following the procedure outlined in the appropriate model/year Service Manual. 3. Remove the transfer case input seal. Clean the seal bore in the transfer case. 4. Install a new Transfer Case Input Seal (F77Z-7B215-AA) 5. If the transmission fluid is burnt, repair the transmission as required and then replace the transfer case seal as outlined in Step 3. PART NUMBER PART NAME F77Z-7B215-AA Transfer case Input Seal OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-20-18 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971213A Replace Transfer Case 1.6 Hrs. Input Seal - 1987-96 F-150-350, Bronco And 1997 F-250-350 971213B Replace Transfer Case 2.7 Hrs. Input Seal - 1996-97 Explorer AWD And 1997 Mountaineer 971213C Replace Transfer Case 2.1 Hrs. Input Seal - 1997 F-150, Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 97-12-13 > Jun > 97 > A/T - Low Transmission Fluid/Shift/Engagement Concerns > Page 7278 Expedition DEALER CODING CONDITION BASIC PART NO. CODE 7B215 D8 OASIS CODES: 501000, 502000, 503000, 504000, 506000, 510000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 97-12-13 > Jun > 97 > A/T - Low Transmission Fluid/Shift/Engagement Concerns Seals and Gaskets: All Technical Service Bulletins A/T - Low Transmission Fluid/Shift/Engagement Concerns Article No. 97-12-13 06/09/97 TRANSMISSION - C6, E4OD, AOD, 4R70W - LOW TRANSMISSION FLUID LEVEL AND/OR SHIFT AND/OR ENGAGEMENT CONCERNS - 4X4 AND AWD VEHICLES ONLY LIGHT TRUCK: 1987-96 BRONCO 1987-97 F-150, F-250, F-350 1996-97 EXPLORER 1997 EXPEDITION, MOUNTAINEER This TSB article is being republished in its entirety to include 1997 model year vehicles. ISSUE: The transmission may have low fluid level and/or may have either a shift concern and/or an engagement concern. This may be caused by transmission fluid leaking from the transmission into the transfer case through the transfer case input seal. ACTION: Replace the transfer case input seal. The new seal should reduce the possibility of fluid leaking from the transmission into the transfer case. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Check the transmission fluid level. It the transmission fluid level is low and there are no visible signs of a leak, check the transfer case fluid level. The level of fluid in the transfer case should be just below the fill plug hole. 2. If the transfer case fluid level is overfull and the transmission fluid is not burnt, remove the transfer case from the vehicle following the procedure outlined in the appropriate model/year Service Manual. 3. Remove the transfer case input seal. Clean the seal bore in the transfer case. 4. Install a new Transfer Case Input Seal (F77Z-7B215-AA) 5. If the transmission fluid is burnt, repair the transmission as required and then replace the transfer case seal as outlined in Step 3. PART NUMBER PART NAME F77Z-7B215-AA Transfer case Input Seal OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-20-18 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971213A Replace Transfer Case 1.6 Hrs. Input Seal - 1987-96 F-150-350, Bronco And 1997 F-250-350 971213B Replace Transfer Case 2.7 Hrs. Input Seal - 1996-97 Explorer AWD And 1997 Mountaineer 971213C Replace Transfer Case 2.1 Hrs. Input Seal - 1997 F-150, Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 97-12-13 > Jun > 97 > A/T - Low Transmission Fluid/Shift/Engagement Concerns > Page 7284 Expedition DEALER CODING CONDITION BASIC PART NO. CODE 7B215 D8 OASIS CODES: 501000, 502000, 503000, 504000, 506000, 510000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 7285 Seals and Gaskets: By Symptom Technical Service Bulletin # 97-12-13 Date: 970609 A/T - Low Transmission Fluid/Shift/Engagement Concerns Article No. 97-12-13 06/09/97 TRANSMISSION - C6, E4OD, AOD, 4R70W - LOW TRANSMISSION FLUID LEVEL AND/OR SHIFT AND/OR ENGAGEMENT CONCERNS - 4X4 AND AWD VEHICLES ONLY LIGHT TRUCK: 1987-96 BRONCO 1987-97 F-150, F-250, F-350 1996-97 EXPLORER 1997 EXPEDITION, MOUNTAINEER This TSB article is being republished in its entirety to include 1997 model year vehicles. ISSUE: The transmission may have low fluid level and/or may have either a shift concern and/or an engagement concern. This may be caused by transmission fluid leaking from the transmission into the transfer case through the transfer case input seal. ACTION: Replace the transfer case input seal. The new seal should reduce the possibility of fluid leaking from the transmission into the transfer case. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Check the transmission fluid level. It the transmission fluid level is low and there are no visible signs of a leak, check the transfer case fluid level. The level of fluid in the transfer case should be just below the fill plug hole. 2. If the transfer case fluid level is overfull and the transmission fluid is not burnt, remove the transfer case from the vehicle following the procedure outlined in the appropriate model/year Service Manual. 3. Remove the transfer case input seal. Clean the seal bore in the transfer case. 4. Install a new Transfer Case Input Seal (F77Z-7B215-AA) 5. If the transmission fluid is burnt, repair the transmission as required and then replace the transfer case seal as outlined in Step 3. PART NUMBER PART NAME F77Z-7B215-AA Transfer case Input Seal OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-20-18 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971213A Replace Transfer Case 1.6 Hrs. Input Seal - 1987-96 F-150-350, Bronco And 1997 F-250-350 971213B Replace Transfer Case 2.7 Hrs. Input Seal - 1996-97 Explorer AWD And 1997 Mountaineer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 7286 971213C Replace Transfer Case 2.1 Hrs. Input Seal - 1997 F-150, Expedition DEALER CODING CONDITION BASIC PART NO. CODE 7B215 D8 OASIS CODES: 501000, 502000, 503000, 504000, 506000, 510000 Technical Service Bulletin # 97-12-13 Date: 970609 A/T - Low Transmission Fluid/Shift/Engagement Concerns Article No. 97-12-13 06/09/97 TRANSMISSION - C6, E4OD, AOD, 4R70W - LOW TRANSMISSION FLUID LEVEL AND/OR SHIFT AND/OR ENGAGEMENT CONCERNS - 4X4 AND AWD VEHICLES ONLY LIGHT TRUCK: 1987-96 BRONCO 1987-97 F-150, F-250, F-350 1996-97 EXPLORER 1997 EXPEDITION, MOUNTAINEER This TSB article is being republished in its entirety to include 1997 model year vehicles. ISSUE: The transmission may have low fluid level and/or may have either a shift concern and/or an engagement concern. This may be caused by transmission fluid leaking from the transmission into the transfer case through the transfer case input seal. ACTION: Replace the transfer case input seal. The new seal should reduce the possibility of fluid leaking from the transmission into the transfer case. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Check the transmission fluid level. It the transmission fluid level is low and there are no visible signs of a leak, check the transfer case fluid level. The level of fluid in the transfer case should be just below the fill plug hole. 2. If the transfer case fluid level is overfull and the transmission fluid is not burnt, remove the transfer case from the vehicle following the procedure outlined in the appropriate model/year Service Manual. 3. Remove the transfer case input seal. Clean the seal bore in the transfer case. 4. Install a new Transfer Case Input Seal (F77Z-7B215-AA) 5. If the transmission fluid is burnt, repair the transmission as required and then replace the transfer case seal as outlined in Step 3. PART NUMBER PART NAME F77Z-7B215-AA Transfer case Input Seal OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-20-18 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 7287 971213A Replace Transfer Case 1.6 Hrs. Input Seal - 1987-96 F-150-350, Bronco And 1997 F-250-350 971213B Replace Transfer Case 2.7 Hrs. Input Seal - 1996-97 Explorer AWD And 1997 Mountaineer 971213C Replace Transfer Case 2.1 Hrs. Input Seal - 1997 F-150, Expedition DEALER CODING CONDITION BASIC PART NO. CODE 7B215 D8 OASIS CODES: 501000, 502000, 503000, 504000, 506000, 510000 Technical Service Bulletin # 97-12-13 Date: 970609 A/T - Low Transmission Fluid/Shift/Engagement Concerns Article No. 97-12-13 06/09/97 TRANSMISSION - C6, E4OD, AOD, 4R70W - LOW TRANSMISSION FLUID LEVEL AND/OR SHIFT AND/OR ENGAGEMENT CONCERNS - 4X4 AND AWD VEHICLES ONLY LIGHT TRUCK: 1987-96 BRONCO 1987-97 F-150, F-250, F-350 1996-97 EXPLORER 1997 EXPEDITION, MOUNTAINEER This TSB article is being republished in its entirety to include 1997 model year vehicles. ISSUE: The transmission may have low fluid level and/or may have either a shift concern and/or an engagement concern. This may be caused by transmission fluid leaking from the transmission into the transfer case through the transfer case input seal. ACTION: Replace the transfer case input seal. The new seal should reduce the possibility of fluid leaking from the transmission into the transfer case. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Check the transmission fluid level. It the transmission fluid level is low and there are no visible signs of a leak, check the transfer case fluid level. The level of fluid in the transfer case should be just below the fill plug hole. 2. If the transfer case fluid level is overfull and the transmission fluid is not burnt, remove the transfer case from the vehicle following the procedure outlined in the appropriate model/year Service Manual. 3. Remove the transfer case input seal. Clean the seal bore in the transfer case. 4. Install a new Transfer Case Input Seal (F77Z-7B215-AA) 5. If the transmission fluid is burnt, repair the transmission as required and then replace the transfer case seal as outlined in Step 3. PART NUMBER PART NAME Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 7288 F77Z-7B215-AA Transfer case Input Seal OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-20-18 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971213A Replace Transfer Case 1.6 Hrs. Input Seal - 1987-96 F-150-350, Bronco And 1997 F-250-350 971213B Replace Transfer Case 2.7 Hrs. Input Seal - 1996-97 Explorer AWD And 1997 Mountaineer 971213C Replace Transfer Case 2.1 Hrs. Input Seal - 1997 F-150, Expedition DEALER CODING CONDITION BASIC PART NO. CODE 7B215 D8 OASIS CODES: 501000, 502000, 503000, 504000, 506000, 510000 Technical Service Bulletin # 97-12-13 Date: 970609 A/T - Low Transmission Fluid/Shift/Engagement Concerns Article No. 97-12-13 06/09/97 TRANSMISSION - C6, E4OD, AOD, 4R70W - LOW TRANSMISSION FLUID LEVEL AND/OR SHIFT AND/OR ENGAGEMENT CONCERNS - 4X4 AND AWD VEHICLES ONLY LIGHT TRUCK: 1987-96 BRONCO 1987-97 F-150, F-250, F-350 1996-97 EXPLORER 1997 EXPEDITION, MOUNTAINEER This TSB article is being republished in its entirety to include 1997 model year vehicles. ISSUE: The transmission may have low fluid level and/or may have either a shift concern and/or an engagement concern. This may be caused by transmission fluid leaking from the transmission into the transfer case through the transfer case input seal. ACTION: Replace the transfer case input seal. The new seal should reduce the possibility of fluid leaking from the transmission into the transfer case. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Check the transmission fluid level. It the transmission fluid level is low and there are no visible signs of a leak, check the transfer case fluid level. The level of fluid in the transfer case should be just below the fill plug hole. 2. If the transfer case fluid level is overfull and the transmission fluid is not burnt, remove the transfer case from the vehicle following the procedure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 7289 outlined in the appropriate model/year Service Manual. 3. Remove the transfer case input seal. Clean the seal bore in the transfer case. 4. Install a new Transfer Case Input Seal (F77Z-7B215-AA) 5. If the transmission fluid is burnt, repair the transmission as required and then replace the transfer case seal as outlined in Step 3. PART NUMBER PART NAME F77Z-7B215-AA Transfer case Input Seal OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-20-18 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971213A Replace Transfer Case 1.6 Hrs. Input Seal - 1987-96 F-150-350, Bronco And 1997 F-250-350 971213B Replace Transfer Case 2.7 Hrs. Input Seal - 1996-97 Explorer AWD And 1997 Mountaineer 971213C Replace Transfer Case 2.1 Hrs. Input Seal - 1997 F-150, Expedition DEALER CODING CONDITION BASIC PART NO. CODE 7B215 D8 OASIS CODES: 501000, 502000, 503000, 504000, 506000, 510000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Technical Service Bulletins > Page 7290 Seals and Gaskets: Service and Repair REMOVAL 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE, THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Remove the rear driveshaft. (1) Remove the four rear driveshaft flange bolts. (2) Remove the rear driveshaft. 3. Remove the rear oil seal. - Use (A) Seal Remover and (B) Slide Hammer. INSTALLATION 1. To install the rear oil seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Technical Service Bulletins > Page 7291 - Use Seal Replacer. 2. Install the rear driveshaft. (1) Position the rear driveshaft. (2) Install the four rear driveshaft flange bolts. 3. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Technical Service Bulletins > Page 7292 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Customer Interest: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions Four Wheel Drive Selector Switch: Customer Interest Transfer Case - Multiple Electrical Malfunctions Article No. 01-16-6 08/20/01 ^ LAMP - 4X4 "LOW RANGE" LIGHT DIMLY LIT ^ SWITCHES - TRANSFER CASE MODE SWITCH - 4X4 HI/LOW SWITCH SHORTED OUT ^ WINDSHIELD WIPERS - INTERMITTENT WIPERS ERRATIC OR INOPERABLE ^ TRANSFER CASE - WATER PRESENT IN TRANSFER CASE FORD: 1997 EXPEDITION, F-150, F-250 LD This article is being republished in its entirety to update the labor time. ISSUE Water may be present in the transfer case on some vehicles. This may cause: ^ Transfer Case Mode Switch to become inoperative ^ The 4X4 "Low Range" light to appear dimly lit ^ The intermittent wipers to become erratic or inoperative ^ Vehicle Speed Sensor (VSS) Diagnostic Trouble Codes (DTCs) P0500, P0503, P1500, and P1501 to be set. This may be caused by water splashing into the transfer case through the vent tube assembly, possibly causing the transfer case mode switch to short out, and/or the VSS gear to swell and set the VSS DTCs listed above. Shorting out the transfer case mode switch may cause the intermittent wiper mode to function erratically, as well as possibly causing the 4X4 light to work incorrectly. ACTION Inspect, diagnose, and/or replace the necessary components. Refer to the following Service Procedure for details. SERVICE PROCEDURE Procedure for VSS Gear: 1. Inspect VSS gear in the transfer case for looseness. 2. Replace Gear (C80Z-17285-B) as necessary. Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Mode Switch: 1. Check resistance of the Transfer Case Mode Switch. 2. The resistance of the switch should be at least 100,000 ohms. If it is less, replace the switch (3-Position Switch, E7TZ-7E440-A, manual shift only). Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Vent Replacement: 1. Remove old vent hose from fitting on front of transfer case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Customer Interest: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 7302 2. Attach end of new Vent Hose (F75Z-7A246-M) to fitting, and route the hose up over the top of the transfer case (Figure 1). 3. Attach the clip on the vent hose to the top of the vertical rib on the transfer case extension housing to support the end of the hose (Figure 2). NOTE FOR ALL WATER CONCERNS, DRAIN AND REFILL THE TRANSFER CASE WITH FRESH FLUID (XT-2-QDX), AND REPLACE THE VENT HOSE WITH THE REVISED PART. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Customer Interest: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 7303 SUPERSEDES:97-11-19 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011606A Drain And Refill Transfer 1.2 Hrs. Case, Inspect And/Or Replace VSS Gear And Transfer Case Mode Switch, And Install Vent Kit DEALER CODING CONDITION BASIC PART NO. CODE 7D494 49 OASIS CODES: 202000, 206000, 508000, 508300, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions Four Wheel Drive Selector Switch: All Technical Service Bulletins Transfer Case - Multiple Electrical Malfunctions Article No. 01-16-6 08/20/01 ^ LAMP - 4X4 "LOW RANGE" LIGHT DIMLY LIT ^ SWITCHES - TRANSFER CASE MODE SWITCH - 4X4 HI/LOW SWITCH SHORTED OUT ^ WINDSHIELD WIPERS - INTERMITTENT WIPERS ERRATIC OR INOPERABLE ^ TRANSFER CASE - WATER PRESENT IN TRANSFER CASE FORD: 1997 EXPEDITION, F-150, F-250 LD This article is being republished in its entirety to update the labor time. ISSUE Water may be present in the transfer case on some vehicles. This may cause: ^ Transfer Case Mode Switch to become inoperative ^ The 4X4 "Low Range" light to appear dimly lit ^ The intermittent wipers to become erratic or inoperative ^ Vehicle Speed Sensor (VSS) Diagnostic Trouble Codes (DTCs) P0500, P0503, P1500, and P1501 to be set. This may be caused by water splashing into the transfer case through the vent tube assembly, possibly causing the transfer case mode switch to short out, and/or the VSS gear to swell and set the VSS DTCs listed above. Shorting out the transfer case mode switch may cause the intermittent wiper mode to function erratically, as well as possibly causing the 4X4 light to work incorrectly. ACTION Inspect, diagnose, and/or replace the necessary components. Refer to the following Service Procedure for details. SERVICE PROCEDURE Procedure for VSS Gear: 1. Inspect VSS gear in the transfer case for looseness. 2. Replace Gear (C80Z-17285-B) as necessary. Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Mode Switch: 1. Check resistance of the Transfer Case Mode Switch. 2. The resistance of the switch should be at least 100,000 ohms. If it is less, replace the switch (3-Position Switch, E7TZ-7E440-A, manual shift only). Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Vent Replacement: 1. Remove old vent hose from fitting on front of transfer case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 7309 2. Attach end of new Vent Hose (F75Z-7A246-M) to fitting, and route the hose up over the top of the transfer case (Figure 1). 3. Attach the clip on the vent hose to the top of the vertical rib on the transfer case extension housing to support the end of the hose (Figure 2). NOTE FOR ALL WATER CONCERNS, DRAIN AND REFILL THE TRANSFER CASE WITH FRESH FLUID (XT-2-QDX), AND REPLACE THE VENT HOSE WITH THE REVISED PART. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 7310 SUPERSEDES:97-11-19 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011606A Drain And Refill Transfer 1.2 Hrs. Case, Inspect And/Or Replace VSS Gear And Transfer Case Mode Switch, And Install Vent Kit DEALER CODING CONDITION BASIC PART NO. CODE 7D494 49 OASIS CODES: 202000, 206000, 508000, 508300, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Four Wheel Drive Selector Switch: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold Valve: All Technical Service Bulletins Engine - Rough Idle/Noise When Cold Article No. 00-26-1 12/25/00 ^ ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 ^ NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 FORD: 1997-1999 F-250 LD 1997-2000 ECONOLINE, EXCURSION, EXPEDITION, F-150 1999-2000 F SUPER DUTY LINCOLN: 1998-1999 NAVIGATOR ISSUE Some vehicles equipped with a 4.6L, 5.4L, or 6.8L engine may exhibit a rough idle/miss after start-up in cold ambient temperatures (less than -12°C/10 ° F). This may be caused by a roller finger follower(s) being dislodged from the valve. This may result in damage to the camshaft, roller finger follower, valve, retainer, etc. A procedure is now available to service this condition. ACTION Inspect and replace any worn or damaged engine valve components and install new retaining clip and lash adjuster for service. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform normal engine diagnostic routines before opening valve covers. If the valve train is suspect, remove the valve covers and look for Roller Finger Follower(s) (RFF) that may have become dislodged. 1. Inspect the following parts that may have been damaged by any dislodged roller finger followers: ^ Cam lobes (chipped or grooved) ^ Valve stem tips (mushroomed, metal displaced, or bent) ^ Roller finger followers (chipped or grooved) ^ Inspect valve guide only if its corresponding RFF or valve stem tip is damaged. Replace damaged parts as necessary. 2. If follower(s) are damaged, replaced as necessary, otherwise re-use followers in same location as removed from head. 3. Remove all intake and exhaust lash adjusters from the engine and replace with service-only Lash Adjusters (YL3Z-6500-AA). Refer to the appropriate workshop Manual, Section 303-01B for service procedures and tooling necessary to compress the valve springs and remove the roller followers. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Four Wheel Drive Selector Switch: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 7316 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Four Wheel Drive Selector Switch: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 7317 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Four Wheel Drive Selector Switch: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 7323 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Four Wheel Drive Selector Switch: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 7324 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Page 7325 Four Wheel Drive Selector Switch: Specifications TORQUE SPECIFICATIONS Shift Range Selector Switch Screws ........................................................................................................................................... 2-3 Nm (18-26 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Page 7326 4 Wheel Drive Mode Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Page 7327 Four Wheel Drive Selector Switch: Description and Operation The 4WD mode switch is a rotary switch which allows the vehicle operator to choose between 2WD, A4WD, 4WD HIGH, and LOW range positions. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Page 7328 Four Wheel Drive Selector Switch: Service and Repair REMOVAL 1. Remove the center instrument panel trim plate. 2. Remove the shift range selector switch. (1) Remove the shift range selector switch knob. (2) Disconnect the shift range selector switch electrical connector. (3) Remove the two shift range selector switch screws. (4) Remove the shift range selector switch. INSTALLATION 1. Install the shift range selector switch. (1) Position the shift range selector switch. (2) Install the bolts. (3) Install the electrical connectors. (4) Install the knob. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Page 7329 2. Install the center instrument panel trim panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Speed Sensor: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions Speed Sensor: Customer Interest Transfer Case - Multiple Electrical Malfunctions Article No. 01-16-6 08/20/01 ^ LAMP - 4X4 "LOW RANGE" LIGHT DIMLY LIT ^ SWITCHES - TRANSFER CASE MODE SWITCH - 4X4 HI/LOW SWITCH SHORTED OUT ^ WINDSHIELD WIPERS - INTERMITTENT WIPERS ERRATIC OR INOPERABLE ^ TRANSFER CASE - WATER PRESENT IN TRANSFER CASE FORD: 1997 EXPEDITION, F-150, F-250 LD This article is being republished in its entirety to update the labor time. ISSUE Water may be present in the transfer case on some vehicles. This may cause: ^ Transfer Case Mode Switch to become inoperative ^ The 4X4 "Low Range" light to appear dimly lit ^ The intermittent wipers to become erratic or inoperative ^ Vehicle Speed Sensor (VSS) Diagnostic Trouble Codes (DTCs) P0500, P0503, P1500, and P1501 to be set. This may be caused by water splashing into the transfer case through the vent tube assembly, possibly causing the transfer case mode switch to short out, and/or the VSS gear to swell and set the VSS DTCs listed above. Shorting out the transfer case mode switch may cause the intermittent wiper mode to function erratically, as well as possibly causing the 4X4 light to work incorrectly. ACTION Inspect, diagnose, and/or replace the necessary components. Refer to the following Service Procedure for details. SERVICE PROCEDURE Procedure for VSS Gear: 1. Inspect VSS gear in the transfer case for looseness. 2. Replace Gear (C80Z-17285-B) as necessary. Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Mode Switch: 1. Check resistance of the Transfer Case Mode Switch. 2. The resistance of the switch should be at least 100,000 ohms. If it is less, replace the switch (3-Position Switch, E7TZ-7E440-A, manual shift only). Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Vent Replacement: 1. Remove old vent hose from fitting on front of transfer case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Speed Sensor: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 7338 2. Attach end of new Vent Hose (F75Z-7A246-M) to fitting, and route the hose up over the top of the transfer case (Figure 1). 3. Attach the clip on the vent hose to the top of the vertical rib on the transfer case extension housing to support the end of the hose (Figure 2). NOTE FOR ALL WATER CONCERNS, DRAIN AND REFILL THE TRANSFER CASE WITH FRESH FLUID (XT-2-QDX), AND REPLACE THE VENT HOSE WITH THE REVISED PART. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Speed Sensor: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 7339 SUPERSEDES:97-11-19 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011606A Drain And Refill Transfer 1.2 Hrs. Case, Inspect And/Or Replace VSS Gear And Transfer Case Mode Switch, And Install Vent Kit DEALER CODING CONDITION BASIC PART NO. CODE 7D494 49 OASIS CODES: 202000, 206000, 508000, 508300, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions Speed Sensor: All Technical Service Bulletins Transfer Case - Multiple Electrical Malfunctions Article No. 01-16-6 08/20/01 ^ LAMP - 4X4 "LOW RANGE" LIGHT DIMLY LIT ^ SWITCHES - TRANSFER CASE MODE SWITCH - 4X4 HI/LOW SWITCH SHORTED OUT ^ WINDSHIELD WIPERS - INTERMITTENT WIPERS ERRATIC OR INOPERABLE ^ TRANSFER CASE - WATER PRESENT IN TRANSFER CASE FORD: 1997 EXPEDITION, F-150, F-250 LD This article is being republished in its entirety to update the labor time. ISSUE Water may be present in the transfer case on some vehicles. This may cause: ^ Transfer Case Mode Switch to become inoperative ^ The 4X4 "Low Range" light to appear dimly lit ^ The intermittent wipers to become erratic or inoperative ^ Vehicle Speed Sensor (VSS) Diagnostic Trouble Codes (DTCs) P0500, P0503, P1500, and P1501 to be set. This may be caused by water splashing into the transfer case through the vent tube assembly, possibly causing the transfer case mode switch to short out, and/or the VSS gear to swell and set the VSS DTCs listed above. Shorting out the transfer case mode switch may cause the intermittent wiper mode to function erratically, as well as possibly causing the 4X4 light to work incorrectly. ACTION Inspect, diagnose, and/or replace the necessary components. Refer to the following Service Procedure for details. SERVICE PROCEDURE Procedure for VSS Gear: 1. Inspect VSS gear in the transfer case for looseness. 2. Replace Gear (C80Z-17285-B) as necessary. Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Mode Switch: 1. Check resistance of the Transfer Case Mode Switch. 2. The resistance of the switch should be at least 100,000 ohms. If it is less, replace the switch (3-Position Switch, E7TZ-7E440-A, manual shift only). Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Vent Replacement: 1. Remove old vent hose from fitting on front of transfer case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 7345 2. Attach end of new Vent Hose (F75Z-7A246-M) to fitting, and route the hose up over the top of the transfer case (Figure 1). 3. Attach the clip on the vent hose to the top of the vertical rib on the transfer case extension housing to support the end of the hose (Figure 2). NOTE FOR ALL WATER CONCERNS, DRAIN AND REFILL THE TRANSFER CASE WITH FRESH FLUID (XT-2-QDX), AND REPLACE THE VENT HOSE WITH THE REVISED PART. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 7346 SUPERSEDES:97-11-19 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011606A Drain And Refill Transfer 1.2 Hrs. Case, Inspect And/Or Replace VSS Gear And Transfer Case Mode Switch, And Install Vent Kit DEALER CODING CONDITION BASIC PART NO. CODE 7D494 49 OASIS CODES: 202000, 206000, 508000, 508300, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Page 7347 Speed Sensor: Specifications TORQUE SPECIFICATIONS Output Speed Sensor Bolt ........................................................................................................................................................... 3-6 Nm (27-53 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Speed Sensor: > 01-16-6 > Aug > 01 > Transfer Case Multiple Electrical Malfunctions Speed Sensor: Customer Interest Transfer Case - Multiple Electrical Malfunctions Article No. 01-16-6 08/20/01 ^ LAMP - 4X4 "LOW RANGE" LIGHT DIMLY LIT ^ SWITCHES - TRANSFER CASE MODE SWITCH - 4X4 HI/LOW SWITCH SHORTED OUT ^ WINDSHIELD WIPERS - INTERMITTENT WIPERS ERRATIC OR INOPERABLE ^ TRANSFER CASE - WATER PRESENT IN TRANSFER CASE FORD: 1997 EXPEDITION, F-150, F-250 LD This article is being republished in its entirety to update the labor time. ISSUE Water may be present in the transfer case on some vehicles. This may cause: ^ Transfer Case Mode Switch to become inoperative ^ The 4X4 "Low Range" light to appear dimly lit ^ The intermittent wipers to become erratic or inoperative ^ Vehicle Speed Sensor (VSS) Diagnostic Trouble Codes (DTCs) P0500, P0503, P1500, and P1501 to be set. This may be caused by water splashing into the transfer case through the vent tube assembly, possibly causing the transfer case mode switch to short out, and/or the VSS gear to swell and set the VSS DTCs listed above. Shorting out the transfer case mode switch may cause the intermittent wiper mode to function erratically, as well as possibly causing the 4X4 light to work incorrectly. ACTION Inspect, diagnose, and/or replace the necessary components. Refer to the following Service Procedure for details. SERVICE PROCEDURE Procedure for VSS Gear: 1. Inspect VSS gear in the transfer case for looseness. 2. Replace Gear (C80Z-17285-B) as necessary. Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Mode Switch: 1. Check resistance of the Transfer Case Mode Switch. 2. The resistance of the switch should be at least 100,000 ohms. If it is less, replace the switch (3-Position Switch, E7TZ-7E440-A, manual shift only). Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Vent Replacement: 1. Remove old vent hose from fitting on front of transfer case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Speed Sensor: > 01-16-6 > Aug > 01 > Transfer Case Multiple Electrical Malfunctions > Page 7356 2. Attach end of new Vent Hose (F75Z-7A246-M) to fitting, and route the hose up over the top of the transfer case (Figure 1). 3. Attach the clip on the vent hose to the top of the vertical rib on the transfer case extension housing to support the end of the hose (Figure 2). NOTE FOR ALL WATER CONCERNS, DRAIN AND REFILL THE TRANSFER CASE WITH FRESH FLUID (XT-2-QDX), AND REPLACE THE VENT HOSE WITH THE REVISED PART. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Speed Sensor: > 01-16-6 > Aug > 01 > Transfer Case Multiple Electrical Malfunctions > Page 7357 SUPERSEDES:97-11-19 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011606A Drain And Refill Transfer 1.2 Hrs. Case, Inspect And/Or Replace VSS Gear And Transfer Case Mode Switch, And Install Vent Kit DEALER CODING CONDITION BASIC PART NO. CODE 7D494 49 OASIS CODES: 202000, 206000, 508000, 508300, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions Speed Sensor: All Technical Service Bulletins Transfer Case - Multiple Electrical Malfunctions Article No. 01-16-6 08/20/01 ^ LAMP - 4X4 "LOW RANGE" LIGHT DIMLY LIT ^ SWITCHES - TRANSFER CASE MODE SWITCH - 4X4 HI/LOW SWITCH SHORTED OUT ^ WINDSHIELD WIPERS - INTERMITTENT WIPERS ERRATIC OR INOPERABLE ^ TRANSFER CASE - WATER PRESENT IN TRANSFER CASE FORD: 1997 EXPEDITION, F-150, F-250 LD This article is being republished in its entirety to update the labor time. ISSUE Water may be present in the transfer case on some vehicles. This may cause: ^ Transfer Case Mode Switch to become inoperative ^ The 4X4 "Low Range" light to appear dimly lit ^ The intermittent wipers to become erratic or inoperative ^ Vehicle Speed Sensor (VSS) Diagnostic Trouble Codes (DTCs) P0500, P0503, P1500, and P1501 to be set. This may be caused by water splashing into the transfer case through the vent tube assembly, possibly causing the transfer case mode switch to short out, and/or the VSS gear to swell and set the VSS DTCs listed above. Shorting out the transfer case mode switch may cause the intermittent wiper mode to function erratically, as well as possibly causing the 4X4 light to work incorrectly. ACTION Inspect, diagnose, and/or replace the necessary components. Refer to the following Service Procedure for details. SERVICE PROCEDURE Procedure for VSS Gear: 1. Inspect VSS gear in the transfer case for looseness. 2. Replace Gear (C80Z-17285-B) as necessary. Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Mode Switch: 1. Check resistance of the Transfer Case Mode Switch. 2. The resistance of the switch should be at least 100,000 ohms. If it is less, replace the switch (3-Position Switch, E7TZ-7E440-A, manual shift only). Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Vent Replacement: 1. Remove old vent hose from fitting on front of transfer case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 7363 2. Attach end of new Vent Hose (F75Z-7A246-M) to fitting, and route the hose up over the top of the transfer case (Figure 1). 3. Attach the clip on the vent hose to the top of the vertical rib on the transfer case extension housing to support the end of the hose (Figure 2). NOTE FOR ALL WATER CONCERNS, DRAIN AND REFILL THE TRANSFER CASE WITH FRESH FLUID (XT-2-QDX), AND REPLACE THE VENT HOSE WITH THE REVISED PART. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 7364 SUPERSEDES:97-11-19 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011606A Drain And Refill Transfer 1.2 Hrs. Case, Inspect And/Or Replace VSS Gear And Transfer Case Mode Switch, And Install Vent Kit DEALER CODING CONDITION BASIC PART NO. CODE 7D494 49 OASIS CODES: 202000, 206000, 508000, 508300, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Page 7365 Speed Sensor: Specifications TORQUE SPECIFICATIONS Output Speed Sensor Bolt ........................................................................................................................................................... 3-6 Nm (27-53 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speedometer Gear, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Gear: > 98-5-8 > Mar > 98 > MIL ON/DTC P0503/Erratic Speedometer/Shifting Speedometer Gear: Customer Interest MIL ON/DTC P0503/Erratic Speedometer/Shifting Article No. 98-5-8 03/16/98 ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODE (DTC) P0503 STORED IN MEMORY - 4X4 VEHICLES ONLY ^ TRANSMISSION - SHIFT CONCERNS AND/OR ERRATIC SPEEDOMETER OPERATION MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - 4X4 VEHICLES ONLY LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR This TSB article is being republished in its entirety to correct the parts listed. ISSUE: The Malfunction Indicator Lamp (MIL) may illuminate and Diagnostic Trouble Code (DTC) P0503 may be stored in memory. There may also be transmission shift concerns and/or erratic speedometer operation. This may be caused by the speedometer drive gear being loose on the transfer case output shaft. ACTION: Replace the speedometer drive gear. The new gear has a tighter fit and should reduce the possibility of erratic signals. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal diagnostics as outlined in the 1997 or 1998 Powertrain Control/Emissions Diagnosis (PC/ED) On-Board Diagnostics II (OBDII) Service Manual. Service as required. 2. If no concerns were found or the concern is still present, replace the speedometer drive gear. 3. Remove the four (4) rear driveshaft flange bolts and remove the rear driveshaft. NOTE: TO MAINTAIN INITIAL DRIVESHAFT BALANCE, MARK THE REAR DRIVESHAFT YOKE AND AXLE FLANGE SO THEY CAN BE REASSEMBLED IN THEIR ORIGINAL POSITIONS. 4. Remove the six (6) extension housing bolts and remove the rear extension housing. 5. Remove the speedometer gear spacer then push the speedometer drive gear toward the transfer case and remove the steel ball. The speedometer drive gear can now be removed from the output shaft. 6. To install the revised Speedometer Drive Gear (F7TZ-17285-AA), reverse the removal procedure. NOTE: THE NEW SPEEDOMETER DRIVE GEAR WILL HAVE A SLIGHT INTERFERENCE FIT, HOWEVER IT WILL GO ON TO THE OUTPUT SHAFT BY HAND. DO NOT HEAT THE GEAR. 7. Before installing the extension housing, apply a small bead of sealant to the transfer case cover and extension housing mating surfaces. Use Ford Ultra Silicone Sealant (F7TZ-19554-AA or equivalent). 8. Top off transfer case with MERCON® (XT-2-QDX). PART NUMBER PART NAME F7IZ-19554-AA Ultra Silicone Sealant F7TZ-17285-AA Speedometer Drive Gear Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speedometer Gear, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Gear: > 98-5-8 > Mar > 98 > MIL ON/DTC P0503/Erratic Speedometer/Shifting > Page 7374 XT-2-QDX MERCON(R) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-3-17 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 980508A Replace Speedometer 0.8 Hr. Drive Gear DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 33 OASIS CODES: 204000, 204100, 204200, 206000, 501000, 501200, 502000, 508000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speedometer Gear, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Gear: > 98-5-8 > Mar > 98 > MIL ON/DTC P0503/Erratic Speedometer/Shifting Speedometer Gear: All Technical Service Bulletins MIL ON/DTC P0503/Erratic Speedometer/Shifting Article No. 98-5-8 03/16/98 ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODE (DTC) P0503 STORED IN MEMORY - 4X4 VEHICLES ONLY ^ TRANSMISSION - SHIFT CONCERNS AND/OR ERRATIC SPEEDOMETER OPERATION MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - 4X4 VEHICLES ONLY LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR This TSB article is being republished in its entirety to correct the parts listed. ISSUE: The Malfunction Indicator Lamp (MIL) may illuminate and Diagnostic Trouble Code (DTC) P0503 may be stored in memory. There may also be transmission shift concerns and/or erratic speedometer operation. This may be caused by the speedometer drive gear being loose on the transfer case output shaft. ACTION: Replace the speedometer drive gear. The new gear has a tighter fit and should reduce the possibility of erratic signals. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal diagnostics as outlined in the 1997 or 1998 Powertrain Control/Emissions Diagnosis (PC/ED) On-Board Diagnostics II (OBDII) Service Manual. Service as required. 2. If no concerns were found or the concern is still present, replace the speedometer drive gear. 3. Remove the four (4) rear driveshaft flange bolts and remove the rear driveshaft. NOTE: TO MAINTAIN INITIAL DRIVESHAFT BALANCE, MARK THE REAR DRIVESHAFT YOKE AND AXLE FLANGE SO THEY CAN BE REASSEMBLED IN THEIR ORIGINAL POSITIONS. 4. Remove the six (6) extension housing bolts and remove the rear extension housing. 5. Remove the speedometer gear spacer then push the speedometer drive gear toward the transfer case and remove the steel ball. The speedometer drive gear can now be removed from the output shaft. 6. To install the revised Speedometer Drive Gear (F7TZ-17285-AA), reverse the removal procedure. NOTE: THE NEW SPEEDOMETER DRIVE GEAR WILL HAVE A SLIGHT INTERFERENCE FIT, HOWEVER IT WILL GO ON TO THE OUTPUT SHAFT BY HAND. DO NOT HEAT THE GEAR. 7. Before installing the extension housing, apply a small bead of sealant to the transfer case cover and extension housing mating surfaces. Use Ford Ultra Silicone Sealant (F7TZ-19554-AA or equivalent). 8. Top off transfer case with MERCON® (XT-2-QDX). PART NUMBER PART NAME F7IZ-19554-AA Ultra Silicone Sealant F7TZ-17285-AA Speedometer Drive Gear Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speedometer Gear, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Gear: > 98-5-8 > Mar > 98 > MIL ON/DTC P0503/Erratic Speedometer/Shifting > Page 7380 XT-2-QDX MERCON(R) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-3-17 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 980508A Replace Speedometer 0.8 Hr. Drive Gear DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 33 OASIS CODES: 204000, 204100, 204200, 206000, 501000, 501200, 502000, 508000, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Specifications Transfer Case Actuator: Specifications TORQUE SPECIFICATIONS Shift Motor Bolts .................................................................................................................................. .................................... 8-11 Nm (71-98 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 7384 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 7385 Transfer Case Actuator: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 7386 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 7387 Transfer Case Actuator: Description and Operation The shifting operation of the front drive axle is accomplished by activating the vacuum motor from a switch located on the instrument panel. It is recommended that shifting of the front axle should be done with the front wheels in a straight ahead position and during light throttle application. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor Transfer Case Actuator: Service and Repair Transfer Case Shift Motor REMOVAL 1. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. Raise and support the vehicle. 2. Disconnect the shift motor electrical connector. 3. Remove the coil wire from the transfer case shift motor electrical connector. 1 Remove the wire connector spacer. 2 Remove the coil wire and pin. Use proper electrical connector pin remover. 4. Remove the transfer case shift motor. 1 Remove the four bolts. 2 Remove the transfer case shift motor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 7390 1. Install the transfer case shift motor. 1 Position the transfer case shift motor. 2 Install the four bolts. 2. Install the coil wire into the transfer case shift motor electrical connector. 1 Install the coil wire and pin. 2 Install the wire connector spacer. 3. Connect the electric shift motor electrical connector. 4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 7391 Transfer Case Actuator: Service and Repair Vacuum Reservoir REMOVAL 1. Remove the right front fender splash shield. 1 Remove the screws. 2 Remove the pushpins. 3 Remove the right front fender splash shield. 2. Remove the engine vacuum reservoir. 1 Remove the bolts. 2 Disconnect the vacuum harness from the engine vacuum reservoir and remove the engine vacuum reservoir. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 7392 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 7393 Transfer Case Actuator: Service and Repair Auxiliary Vacuum Reservoir REMOVAL 1. Remove the front fender splash shield. 2. Disconnect the vacuum harness from the auxiliary vacuum reservoir and the A/C vacuum reservoir. 3. Slide the vacuum reservoir assembly out of the battery tray. 4. Separate the A/C vacuum reservoir from the auxiliary vacuum reservoir. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair Pressure Regulating Solenoid: Service and Repair REMOVAL 1. Remove the manual control lever shaft. 2. Disconnect the electronic pressure control (EPC) solenoid electrical connector. CAUTION: Do not pull on the wires. This can damage the wires or the connector and can result in transmission solenoid or sensor failure. 3. Remove the EPC solenoid. INSTALLATION 1. Install the EPC solenoid. 2. Connect the electronic pressure control (EPC) solenoid electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Page 7400 3. Install the manual control lever shaft. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications Shift Interlock Solenoid: Specifications TORQUE SPECIFICATIONS Shift Lock Actuator Bolts ...................................................................................................................................................... 7-11 Nm (62.5-98 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 7404 Shift Interlock Solenoid: Service and Repair REMOVAL 1. Remove the steering column. 2. Remove the insert plate and shift lock actuator. (1) Remove the three shift lock actuator bolts. (2) Remove the insert plate and shift lock actuator. 3. Remove the insert plate from the shift lock actuator. - Remove and discard the shift lock actuator clip. NOTE: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced in the field. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams Shift Solenoid: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications Transfer Case Actuator: Specifications TORQUE SPECIFICATIONS Shift Motor Bolts .................................................................................................................................. .................................... 8-11 Nm (71-98 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 7412 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 7413 Transfer Case Actuator: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 7414 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 7415 Transfer Case Actuator: Description and Operation The shifting operation of the front drive axle is accomplished by activating the vacuum motor from a switch located on the instrument panel. It is recommended that shifting of the front axle should be done with the front wheels in a straight ahead position and during light throttle application. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor Transfer Case Actuator: Service and Repair Transfer Case Shift Motor REMOVAL 1. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. Raise and support the vehicle. 2. Disconnect the shift motor electrical connector. 3. Remove the coil wire from the transfer case shift motor electrical connector. 1 Remove the wire connector spacer. 2 Remove the coil wire and pin. Use proper electrical connector pin remover. 4. Remove the transfer case shift motor. 1 Remove the four bolts. 2 Remove the transfer case shift motor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 7418 1. Install the transfer case shift motor. 1 Position the transfer case shift motor. 2 Install the four bolts. 2. Install the coil wire into the transfer case shift motor electrical connector. 1 Install the coil wire and pin. 2 Install the wire connector spacer. 3. Connect the electric shift motor electrical connector. 4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 7419 Transfer Case Actuator: Service and Repair Vacuum Reservoir REMOVAL 1. Remove the right front fender splash shield. 1 Remove the screws. 2 Remove the pushpins. 3 Remove the right front fender splash shield. 2. Remove the engine vacuum reservoir. 1 Remove the bolts. 2 Disconnect the vacuum harness from the engine vacuum reservoir and remove the engine vacuum reservoir. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 7420 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Transfer Case Shift Motor > Page 7421 Transfer Case Actuator: Service and Repair Auxiliary Vacuum Reservoir REMOVAL 1. Remove the front fender splash shield. 2. Disconnect the vacuum harness from the auxiliary vacuum reservoir and the A/C vacuum reservoir. 3. Slide the vacuum reservoir assembly out of the battery tray. 4. Separate the A/C vacuum reservoir from the auxiliary vacuum reservoir. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation The transmission control switch (TCS) is a momentary contact switch. When the switch is pressed, a signal is sent to the powertrain control module (PCM) to allow automatic shifts from first through fourth gears or first through third gears only. The PCM energizes the transmission control indicator lamp (TCIL) when the switch has been pressed to cancel overdrive. The TCIL indicates overdrive cancel mode activated (lamp on) and electronic pressure control (EPC) circuit shorted (lamp flashing) or monitored sensor failure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Page 7427 Overdrive Indicator Lamp: Testing and Inspection The TCIL indicates overdrive cancel mode activated (lamp on), electronic pressure control circuit shorted or monitored sensor failure (lamp flashing). For testing procedures, Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Adjustments Shift Indicator: Adjustments 1. Remove the upper instrument panel steering column cover. 2. Place the transmission control selector lever in the OD position. - Rotate the transmission control selector lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise (a) position). 3. Hang an eight pound weight on the transmission control selector lever. 4. Center the pointer in the middle of the OD position. - Rotate the thumbwheel located on the bottom of the steering column to adjust the pointer. 5. Remove the eight pound weight. 6. Carefully move the shift control selector lever from detent to detent and compare with transmission settings. - Readjust if necessary. 7. Install the upper instrument panel steering column cover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Testing and Inspection Transmission Mode Indicator - A/T: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Testing and Inspection Four Wheel Drive Indicator Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque On Demand Relay Four Wheel Drive Selector Relay: Locations Torque On Demand Relay Instrument Panel View The Torque On Demand Relay is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque On Demand Relay > Page 7444 Four Wheel Drive Selector Relay: Locations Transfer Case Shift Relay Instrument Panel View The Transfer Case Shift Relays are located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Torque On Demand Relay Torque On Demand Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Torque On Demand Relay > Page 7447 Transfer Case Shift Relays Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > E40D Transmission Transmission Control Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > E40D Transmission > Page 7454 Transmission Control Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Page 7455 Overdrive Switch: Description and Operation The transmission control switch (TCS) is a momentary contact switch. When the switch is pressed, a signal is sent to the powertrain control module (PCM) to allow automatic shifts from first through fourth gears or first through third gears only. The PCM energizes the transmission control indicator lamp (TCIL) when the switch has been pressed to cancel overdrive. The TCIL indicates overdrive cancel mode activated (lamp on) and electronic pressure control (EPC) circuit shorted (lamp flashing) or monitored sensor failure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis Overdrive Switch: Flow of Diagnosis 1. Verify the customer concern by operating the transmission external control. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: - Damaged shift lock actuator - Damaged transmission control switch - Failed fuse(s) Damaged wiring harness - Loose or corroded connections 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 7458 Overdrive Switch: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 7459 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 7460 Overdrive Switch: Pinpoint Tests Part 1 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 7461 Part 2 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 7462 Part 3 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 7463 Part 4 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 7464 Part 5 Of 5 Part 1 Of 3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 7465 Part 2 Of 3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 7466 Part 3 Of 3 Part 1 Of 4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 7467 Part 2 Of 4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 7468 Part 3 Of 4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 7469 Part 4 Of 4 Part 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 7470 Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 7471 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Testing and Inspection > Page 7472 Overdrive Switch: Service and Repair REMOVAL 1. Remove the transmission control switch (TCS). (1) Remove the TCS cover. (2) Remove the TCS. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Description and Operation Shift Interlock Switch: Description and Operation The brake shift interlock actuator prevents moving the shift lever out of the PARK position unless the brake pedal is depressed. The actuator receives a signal from the brake on/off (BOO) switch that allows movement of the shift lever. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > New Digital Transmission Range Sensor - Service Tip Transmission Position Switch/Sensor: Technical Service Bulletins New Digital Transmission Range Sensor - Service Tip Article No. 96-24-10 11/18/96 TRANSMISSION - E40D - 4R70W - 4R44E - 5R55E - NEW DIGITAL TRANSMISSION RANGE SENSOR - DIAGNOSIS SERVICE TIP LINCOLN-MERCURY: 1997 MARK VIII LIGHT TRUCK: 1997 AEROSTAR, ECONOLINE, EXPEDITION, EXPLORER, F-150, F-250, MOUNTAINEER ISSUE: Beginning with Job 1 1997, some vehicles will be equipped with a new Digital Transmission Range (DTR) sensor. The DTR sensor is located on the outside of the transmission (Figure 1) at the outer manual lever. ACTION: Refer to the following text to properly diagnose a concern with the DTR sensor. The new DTR sensor completes the start circuit in "Park" and "Neutral," the backup lamp circuit in "Reverse" and the neutral sense circuit (4X4 only) in "Neutral." The DTR sensor also opens/closes a set of four (4) switches that are monitored by the Powertrain Control Module (PCM) to determine the position of the transmission manual lever. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > New Digital Transmission Range Sensor - Service Tip > Page 7480 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > New Digital Transmission Range Sensor - Service Tip > Page 7481 To properly diagnose the DTR sensor, use the NGS, Rotunda Transmission Tester with TR/MLP Cable "E" (Figure 2) and the new DTR Sensor Overlay (Figure 4), while following the procedures outlined in the appropriate model 1997 Service Manual, Section 07-01 or appropriate model 1997 Workshop Manual, Section 307-01. The new DTR Sensor Overlay (007-00131) and updated Tester Manual was sent to all dealers in August 1996. The TR/MLP Cable "E" (007-00111) was sent to all dealers in June 1995 (refer to TSB 95-19-7). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > New Digital Transmission Range Sensor - Service Tip > Page 7482 When using Cable "E" (Figure 3) to diagnose the DTR sensor, the slide switch must be in the "Digital" position and the "Black" 12-pin connector installed on the sensor. Having the slide switch in the incorrect position or using the incorrect 12-pin connector will result in misdiagnosis and possible replacement of a good component. For diagnosis of the DTR sensor, always refer to the appropriate model 1997 Service Manual, Section 07.01 or appropriate model 1997 Workshop Manual, Section 3O7-01 for proper procedure and required equipment. OTHER APPLICABLE ARTICLES: 95-19-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 503000, 503300, 504000, 601300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 7483 Transmission Position Switch/Sensor: Specifications TORQUE SPECIFICATIONS DTR Sensor Bolts ................................................................................................................................ ..................................... 7-10 Nm (62-89 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 7484 Transmission Position Switch/Sensor: Locations Transmission View The Digital Transmission Range Sensor is located at left side of the automatic transmission. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 7485 Digital Transmission Range Sensor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 7486 Transmission Position Switch/Sensor: Adjustments NOTE: Use Digital Transmission Range (DTR) Sensor Alignment Tool to align both TR and DTR sensors. 1. Raise and support vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Disconnect the manual lever shift control cable. 3. Disconnect the TR or DTR electrical connector. 4. Remove the manual control lever. (1) Remove the nut. (2) Remove the lever. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. 5. Loosen the TR or DTR bolts. 6. Use DTR sensor alignment tool, to align the DTR or TR sensor slots. NOTE: Manual shift lever must be in the neutral position. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 7487 7. Tighten the DTR or TR sensor bolts. 8. Install the manual control lever. (1) Position the manual control lever. (2) Install a new manual lever shaft outer nut. 9. With the manual lever in overdrive connect the shift lever control cable. 10. Install the DTR sensor electrical connector. 11. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications TORQUE SPECIFICATIONS Output Shaft Speed (OSS) Sensor Bolt .......................................................................................................................................... 8-16 Nm (6-12 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 7491 Transmission Speed Sensor: Locations Transmission View The Output Shaft Speed Sensor is located at left side of transmission. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 7492 Output Shaft Speed Sensor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Selector Switch: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions Four Wheel Drive Selector Switch: Customer Interest Transfer Case - Multiple Electrical Malfunctions Article No. 01-16-6 08/20/01 ^ LAMP - 4X4 "LOW RANGE" LIGHT DIMLY LIT ^ SWITCHES - TRANSFER CASE MODE SWITCH - 4X4 HI/LOW SWITCH SHORTED OUT ^ WINDSHIELD WIPERS - INTERMITTENT WIPERS ERRATIC OR INOPERABLE ^ TRANSFER CASE - WATER PRESENT IN TRANSFER CASE FORD: 1997 EXPEDITION, F-150, F-250 LD This article is being republished in its entirety to update the labor time. ISSUE Water may be present in the transfer case on some vehicles. This may cause: ^ Transfer Case Mode Switch to become inoperative ^ The 4X4 "Low Range" light to appear dimly lit ^ The intermittent wipers to become erratic or inoperative ^ Vehicle Speed Sensor (VSS) Diagnostic Trouble Codes (DTCs) P0500, P0503, P1500, and P1501 to be set. This may be caused by water splashing into the transfer case through the vent tube assembly, possibly causing the transfer case mode switch to short out, and/or the VSS gear to swell and set the VSS DTCs listed above. Shorting out the transfer case mode switch may cause the intermittent wiper mode to function erratically, as well as possibly causing the 4X4 light to work incorrectly. ACTION Inspect, diagnose, and/or replace the necessary components. Refer to the following Service Procedure for details. SERVICE PROCEDURE Procedure for VSS Gear: 1. Inspect VSS gear in the transfer case for looseness. 2. Replace Gear (C80Z-17285-B) as necessary. Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Mode Switch: 1. Check resistance of the Transfer Case Mode Switch. 2. The resistance of the switch should be at least 100,000 ohms. If it is less, replace the switch (3-Position Switch, E7TZ-7E440-A, manual shift only). Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Vent Replacement: 1. Remove old vent hose from fitting on front of transfer case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Selector Switch: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 7502 2. Attach end of new Vent Hose (F75Z-7A246-M) to fitting, and route the hose up over the top of the transfer case (Figure 1). 3. Attach the clip on the vent hose to the top of the vertical rib on the transfer case extension housing to support the end of the hose (Figure 2). NOTE FOR ALL WATER CONCERNS, DRAIN AND REFILL THE TRANSFER CASE WITH FRESH FLUID (XT-2-QDX), AND REPLACE THE VENT HOSE WITH THE REVISED PART. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Selector Switch: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 7503 SUPERSEDES:97-11-19 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011606A Drain And Refill Transfer 1.2 Hrs. Case, Inspect And/Or Replace VSS Gear And Transfer Case Mode Switch, And Install Vent Kit DEALER CODING CONDITION BASIC PART NO. CODE 7D494 49 OASIS CODES: 202000, 206000, 508000, 508300, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Selector Switch: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions Four Wheel Drive Selector Switch: All Technical Service Bulletins Transfer Case - Multiple Electrical Malfunctions Article No. 01-16-6 08/20/01 ^ LAMP - 4X4 "LOW RANGE" LIGHT DIMLY LIT ^ SWITCHES - TRANSFER CASE MODE SWITCH - 4X4 HI/LOW SWITCH SHORTED OUT ^ WINDSHIELD WIPERS - INTERMITTENT WIPERS ERRATIC OR INOPERABLE ^ TRANSFER CASE - WATER PRESENT IN TRANSFER CASE FORD: 1997 EXPEDITION, F-150, F-250 LD This article is being republished in its entirety to update the labor time. ISSUE Water may be present in the transfer case on some vehicles. This may cause: ^ Transfer Case Mode Switch to become inoperative ^ The 4X4 "Low Range" light to appear dimly lit ^ The intermittent wipers to become erratic or inoperative ^ Vehicle Speed Sensor (VSS) Diagnostic Trouble Codes (DTCs) P0500, P0503, P1500, and P1501 to be set. This may be caused by water splashing into the transfer case through the vent tube assembly, possibly causing the transfer case mode switch to short out, and/or the VSS gear to swell and set the VSS DTCs listed above. Shorting out the transfer case mode switch may cause the intermittent wiper mode to function erratically, as well as possibly causing the 4X4 light to work incorrectly. ACTION Inspect, diagnose, and/or replace the necessary components. Refer to the following Service Procedure for details. SERVICE PROCEDURE Procedure for VSS Gear: 1. Inspect VSS gear in the transfer case for looseness. 2. Replace Gear (C80Z-17285-B) as necessary. Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Mode Switch: 1. Check resistance of the Transfer Case Mode Switch. 2. The resistance of the switch should be at least 100,000 ohms. If it is less, replace the switch (3-Position Switch, E7TZ-7E440-A, manual shift only). Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Vent Replacement: 1. Remove old vent hose from fitting on front of transfer case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Selector Switch: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 7509 2. Attach end of new Vent Hose (F75Z-7A246-M) to fitting, and route the hose up over the top of the transfer case (Figure 1). 3. Attach the clip on the vent hose to the top of the vertical rib on the transfer case extension housing to support the end of the hose (Figure 2). NOTE FOR ALL WATER CONCERNS, DRAIN AND REFILL THE TRANSFER CASE WITH FRESH FLUID (XT-2-QDX), AND REPLACE THE VENT HOSE WITH THE REVISED PART. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Selector Switch: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 7510 SUPERSEDES:97-11-19 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011606A Drain And Refill Transfer 1.2 Hrs. Case, Inspect And/Or Replace VSS Gear And Transfer Case Mode Switch, And Install Vent Kit DEALER CODING CONDITION BASIC PART NO. CODE 7D494 49 OASIS CODES: 202000, 206000, 508000, 508300, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Page 7511 Four Wheel Drive Selector Switch: Specifications TORQUE SPECIFICATIONS Shift Range Selector Switch Screws ........................................................................................................................................... 2-3 Nm (18-26 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Page 7512 4 Wheel Drive Mode Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Page 7513 Four Wheel Drive Selector Switch: Description and Operation The 4WD mode switch is a rotary switch which allows the vehicle operator to choose between 2WD, A4WD, 4WD HIGH, and LOW range positions. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Page 7514 Four Wheel Drive Selector Switch: Service and Repair REMOVAL 1. Remove the center instrument panel trim plate. 2. Remove the shift range selector switch. (1) Remove the shift range selector switch knob. (2) Disconnect the shift range selector switch electrical connector. (3) Remove the two shift range selector switch screws. (4) Remove the shift range selector switch. INSTALLATION 1. Install the shift range selector switch. (1) Position the shift range selector switch. (2) Install the bolts. (3) Install the electrical connectors. (4) Install the knob. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Technical Service Bulletins > Page 7515 2. Install the center instrument panel trim panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Speed Sensor: > 01-16-6 > Aug > 01 > Transfer Case Multiple Electrical Malfunctions Speed Sensor: Customer Interest Transfer Case - Multiple Electrical Malfunctions Article No. 01-16-6 08/20/01 ^ LAMP - 4X4 "LOW RANGE" LIGHT DIMLY LIT ^ SWITCHES - TRANSFER CASE MODE SWITCH - 4X4 HI/LOW SWITCH SHORTED OUT ^ WINDSHIELD WIPERS - INTERMITTENT WIPERS ERRATIC OR INOPERABLE ^ TRANSFER CASE - WATER PRESENT IN TRANSFER CASE FORD: 1997 EXPEDITION, F-150, F-250 LD This article is being republished in its entirety to update the labor time. ISSUE Water may be present in the transfer case on some vehicles. This may cause: ^ Transfer Case Mode Switch to become inoperative ^ The 4X4 "Low Range" light to appear dimly lit ^ The intermittent wipers to become erratic or inoperative ^ Vehicle Speed Sensor (VSS) Diagnostic Trouble Codes (DTCs) P0500, P0503, P1500, and P1501 to be set. This may be caused by water splashing into the transfer case through the vent tube assembly, possibly causing the transfer case mode switch to short out, and/or the VSS gear to swell and set the VSS DTCs listed above. Shorting out the transfer case mode switch may cause the intermittent wiper mode to function erratically, as well as possibly causing the 4X4 light to work incorrectly. ACTION Inspect, diagnose, and/or replace the necessary components. Refer to the following Service Procedure for details. SERVICE PROCEDURE Procedure for VSS Gear: 1. Inspect VSS gear in the transfer case for looseness. 2. Replace Gear (C80Z-17285-B) as necessary. Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Mode Switch: 1. Check resistance of the Transfer Case Mode Switch. 2. The resistance of the switch should be at least 100,000 ohms. If it is less, replace the switch (3-Position Switch, E7TZ-7E440-A, manual shift only). Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Vent Replacement: 1. Remove old vent hose from fitting on front of transfer case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Speed Sensor: > 01-16-6 > Aug > 01 > Transfer Case Multiple Electrical Malfunctions > Page 7524 2. Attach end of new Vent Hose (F75Z-7A246-M) to fitting, and route the hose up over the top of the transfer case (Figure 1). 3. Attach the clip on the vent hose to the top of the vertical rib on the transfer case extension housing to support the end of the hose (Figure 2). NOTE FOR ALL WATER CONCERNS, DRAIN AND REFILL THE TRANSFER CASE WITH FRESH FLUID (XT-2-QDX), AND REPLACE THE VENT HOSE WITH THE REVISED PART. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Speed Sensor: > 01-16-6 > Aug > 01 > Transfer Case Multiple Electrical Malfunctions > Page 7525 SUPERSEDES:97-11-19 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011606A Drain And Refill Transfer 1.2 Hrs. Case, Inspect And/Or Replace VSS Gear And Transfer Case Mode Switch, And Install Vent Kit DEALER CODING CONDITION BASIC PART NO. CODE 7D494 49 OASIS CODES: 202000, 206000, 508000, 508300, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions Speed Sensor: All Technical Service Bulletins Transfer Case - Multiple Electrical Malfunctions Article No. 01-16-6 08/20/01 ^ LAMP - 4X4 "LOW RANGE" LIGHT DIMLY LIT ^ SWITCHES - TRANSFER CASE MODE SWITCH - 4X4 HI/LOW SWITCH SHORTED OUT ^ WINDSHIELD WIPERS - INTERMITTENT WIPERS ERRATIC OR INOPERABLE ^ TRANSFER CASE - WATER PRESENT IN TRANSFER CASE FORD: 1997 EXPEDITION, F-150, F-250 LD This article is being republished in its entirety to update the labor time. ISSUE Water may be present in the transfer case on some vehicles. This may cause: ^ Transfer Case Mode Switch to become inoperative ^ The 4X4 "Low Range" light to appear dimly lit ^ The intermittent wipers to become erratic or inoperative ^ Vehicle Speed Sensor (VSS) Diagnostic Trouble Codes (DTCs) P0500, P0503, P1500, and P1501 to be set. This may be caused by water splashing into the transfer case through the vent tube assembly, possibly causing the transfer case mode switch to short out, and/or the VSS gear to swell and set the VSS DTCs listed above. Shorting out the transfer case mode switch may cause the intermittent wiper mode to function erratically, as well as possibly causing the 4X4 light to work incorrectly. ACTION Inspect, diagnose, and/or replace the necessary components. Refer to the following Service Procedure for details. SERVICE PROCEDURE Procedure for VSS Gear: 1. Inspect VSS gear in the transfer case for looseness. 2. Replace Gear (C80Z-17285-B) as necessary. Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Mode Switch: 1. Check resistance of the Transfer Case Mode Switch. 2. The resistance of the switch should be at least 100,000 ohms. If it is less, replace the switch (3-Position Switch, E7TZ-7E440-A, manual shift only). Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Vent Replacement: 1. Remove old vent hose from fitting on front of transfer case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 7531 2. Attach end of new Vent Hose (F75Z-7A246-M) to fitting, and route the hose up over the top of the transfer case (Figure 1). 3. Attach the clip on the vent hose to the top of the vertical rib on the transfer case extension housing to support the end of the hose (Figure 2). NOTE FOR ALL WATER CONCERNS, DRAIN AND REFILL THE TRANSFER CASE WITH FRESH FLUID (XT-2-QDX), AND REPLACE THE VENT HOSE WITH THE REVISED PART. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speed Sensor: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 7532 SUPERSEDES:97-11-19 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011606A Drain And Refill Transfer 1.2 Hrs. Case, Inspect And/Or Replace VSS Gear And Transfer Case Mode Switch, And Install Vent Kit DEALER CODING CONDITION BASIC PART NO. CODE 7D494 49 OASIS CODES: 202000, 206000, 508000, 508300, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Technical Service Bulletins > Page 7533 Speed Sensor: Specifications TORQUE SPECIFICATIONS Output Speed Sensor Bolt ........................................................................................................................................................... 3-6 Nm (27-53 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Main Relay > Component Information > Locations ABS Main Relay: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Main Relay > Component Information > Locations > Page 7539 Power Distribution Relay Box The 4 Wheel Anti-Lock Brake System Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Service and Repair Braking Sensor/Switch: Service and Repair REMOVAL Disconnect the brake pedal to power brake booster push rod. 1. Remove the self-locking pin. 2. Remove the brake on/off (BOO) switch. 3. Separate the (A) BOO switch from the (B) brake master cylinder push rod. 4. Remove the brake master cylinder push rod spacer. 5. Remove the brake master cylinder push rod bushing. INSTALLATION To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 98-9-15 > May > 98 > ABS Lamp ON/DTC B1342 Stored Electronic Brake Control Module: Customer Interest ABS - Lamp ON/DTC B1342 Stored Article No. 98-9-15 05/11/98 ^ BRAKES - 4WABS - ABS LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) B1342 STORED IN MEMORY AND/OR CODES NOT LISTED IN WORKSHOP MANUAL VEHICLES BUILT THROUGH 2/12/98 ^ LAMP - ABS LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) B1342 STORED IN MEMORY AND/OR CODES NOT LISTED IN WORKSHOP MANUAL - VEHICLES BUILT THROUGH 2/12/98 LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR ISSUE The Anti-lock Brake System (ABS) lamp may illuminate and Diagnostic Trouble Code (DTC) B1342 may be stored in memory and/or New Generation Star (NGS) Tester may read "Invalid Code." This may be caused by the Nonvolatile Random Access Memory (NVRAM) chip inside the anti-lock brake control module not resetting at low residual voltages. ABS brake function may become inoperative, however, normal braking operation will be maintained. ACTION Replace the anti-lock brake control module. Modules with a build date of 2/19/98 or later have been revised to incorporate a new NVRAM chip. Refer to the appropriate Workshop Manual, Section 206-09, for replacement procedures. PART NUMBER PART NAME F75Z-2C065-AA Anti-lock Brake Control Module (F-150) F75Z-20065-BA Anti-lock Brake Control Module (F-250 LD) F7SZ-2C065-CA Anti-lock Brake Control Module (Expedition, Navigator) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 980915A Diagnose And Replace 0.6 Hr. ABS Module - F-Series, Expedition, And Navigator DEALER CODING CONDITION BASIC PART NO. CODE 2C065 42 OASIS CODES: 206000, 301000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-9-15 > May > 98 > ABS - Lamp ON/DTC B1342 Stored Electronic Brake Control Module: All Technical Service Bulletins ABS - Lamp ON/DTC B1342 Stored Article No. 98-9-15 05/11/98 ^ BRAKES - 4WABS - ABS LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) B1342 STORED IN MEMORY AND/OR CODES NOT LISTED IN WORKSHOP MANUAL VEHICLES BUILT THROUGH 2/12/98 ^ LAMP - ABS LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) B1342 STORED IN MEMORY AND/OR CODES NOT LISTED IN WORKSHOP MANUAL - VEHICLES BUILT THROUGH 2/12/98 LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR ISSUE The Anti-lock Brake System (ABS) lamp may illuminate and Diagnostic Trouble Code (DTC) B1342 may be stored in memory and/or New Generation Star (NGS) Tester may read "Invalid Code." This may be caused by the Nonvolatile Random Access Memory (NVRAM) chip inside the anti-lock brake control module not resetting at low residual voltages. ABS brake function may become inoperative, however, normal braking operation will be maintained. ACTION Replace the anti-lock brake control module. Modules with a build date of 2/19/98 or later have been revised to incorporate a new NVRAM chip. Refer to the appropriate Workshop Manual, Section 206-09, for replacement procedures. PART NUMBER PART NAME F75Z-2C065-AA Anti-lock Brake Control Module (F-150) F75Z-20065-BA Anti-lock Brake Control Module (F-250 LD) F7SZ-2C065-CA Anti-lock Brake Control Module (Expedition, Navigator) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 980915A Diagnose And Replace 0.6 Hr. ABS Module - F-Series, Expedition, And Navigator DEALER CODING CONDITION BASIC PART NO. CODE 2C065 42 OASIS CODES: 206000, 301000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Cruise Control Switch: All Technical Service Bulletins Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 7566 Electronic Brake Control Module: Specifications TIGHTENING SPECIFICATIONS Control Module Screws .............................................................................................................................................................. 4-5 Nm (36-44 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 7567 Electronic Brake Control Module: Locations Engine View The 4 Wheel Anti-Lock Brake System Module is located in the left side of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 7568 Electronic Brake Control Module: Diagrams 4 Wheel Anti-Lock Brake System Module (C146) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 7569 4 Wheel Anti-Lock Brake System Module (C147) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 7570 Electronic Brake Control Module: Description and Operation COMPONENTS The Electronic Hydraulic Control Unit (EHCU) consists of the anti-lock brake control module and the hydraulic control unit (HCU). NOTE: The anti-lock brake control module can be replaced if it is inoperative. If the HCU is inoperative, the EHCU must be replaced as an assembly. PURPOSE The EHCU monitors the electromechanical components of the system. Malfunction of the anti-lock brake system will cause the EHCU to shut off or inhibit the system. However, normal power-assisted braking remains. Malfunctions are indicated by the yellow ABS warning indicator in the instrument cluster. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 7571 Electronic Brake Control Module: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the two anti-lock brake control module electrical connectors. 3. Disconnect the pump motor electrica1 connector from the ABS module. 4. Remove the anti-lock brake control module. ^ Remove the screws. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 7572 CAUTION: Ensure that the replacement anti-lock brake control module identification sticker reads EXP. Use of any other module could result in diminished ABS performance. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications TIGHTENING SPECIFICATIONS EHCU Bolts ......................................................................................................................................... ...................................... 30-40 Nm (23-29 ft. lbs.) EHCU Bracket Bolts ............................................. ..................................................................................................................... 17-23 Nm (13-16 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 7576 Hydraulic Control Assembly - Antilock Brakes: Description and Operation OPERATION When the brakes are applied, brake fluid is forced from the brake master cylinder outlet ports to the Hydraulic Control Unit (HCU) inlet ports. The fluid pressure is transmitted through three normally open solenoid valves inside the HCU, through the outlet ports of HCU to the rear brakes. One circuit of the brake master cylinder feeds the front brakes, while the other circuit feeds the rear brakes. If the Electro-Hydraulic Control Unit ( EHCU) senses that a wheel is about to lock, based on wheel speed sensor data, the solenoid valve will pulse closed preventing more fluid from entering that circuit. The HCU then reads the sensor signal from the affected wheel again. If the wheel is still decelerating, the normally closed solenoid valve for that circuit is opened. Any remaining pressure between the normally open valve and the brake is relieved into the HCU accumulator. Once the affected wheel returns to vehicle speed, the HCU returns the solenoid valves to their normal condition allowing fluid flow to the affected brake. Brake Pulsation During the 4WABS operation, the driver may feel a pulsation in the brake pedal, accompanied by a slight up and down movement in the pedal height. In addition, a mechanical noise from the engine compartment may be heard. The pedal effort and pedal feel during normal braking are similar to that of a conventional power brake system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 7577 Hydraulic Control Assembly - Antilock Brakes: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the anti-lock brake control module electrica1 connectors. 3. Disconnect the hydraulic brake tubes. a. Disconnect the two inlet hydraulic brake tubes. b. Disconnect the three outlet hydraulic brake tubes. WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. CAUTION: ^ Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. ^ Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: Plug each open port to prevent brake fluid from spilling. 4. Remove the Electro-Hydraulic Control Unit (EHCU). a. Remove the bolts. b. Remove the EHCU. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 7578 5. If necessary, remove the EHCU bracket. a. Remove the bolts. b. Remove the EHCU bracket. INSTALLATION 1. If removed, install the EHCU bracket. a. Position the bracket. b. Install the EHCU bracket bolts. 2. Install the EHCU. a. Position the EHCU. b. Install the bolts. 3. Connect the hydraulic brake tubes. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 7579 CAUTION: Only Ford authorized inlet hydraulic brake tubes should be used. These tubes are of specific design and should only be replaced with authorized service parts. 4. Connect the two anti-lock brake control module electrical connectors. 5. Connect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 6. Bleed the brake hydraulic system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Anti-Lock Brake Sensor Screws 63-80 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Differential Speed Sensor Wheel Speed Sensor: Locations Differential Speed Sensor Body View The Differential Speed Sensor is located on rear axle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Differential Speed Sensor > Page 7585 Wheel Speed Sensor: Locations Wheel Speed Sensor Left Front Engine View The Left Front Wheel 4 Wheel Anti-Lock Brake System Sensor is located at the left front wheel. Right Front Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Differential Speed Sensor > Page 7586 Engine View The Right Front Wheel 4 Wheel Anti-Lock Brake System Sensor is located at the Right front wheel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring Wheel Speed Sensor: Service and Repair Toothed Ring Rear The differential case must be disassembled and assembled to replace the rear sensor indicator. Refer to Transmission and Drivetrain for details. Removal and Installation The front brake anti-lock sensor indicator is integral to the front wheel hub. Refer to Transmission and Drivetrain for details. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 7589 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Front REMOVAL 1. Disconnect the front brake anti-lock sensor electrical connector. 2. Remove the front disc brake rotor shield. 3. Remove the (A) two front brake anti-lock sensor bolts and the (B) front brake anti-lock sensor. INSTALLATION 1. To install, reverse the removal procedure. Rear REMOVAL Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 7590 Remove the rear brake anti-lock sensor. 1. Disconnect the electrical connector. 2. Remove the bolt. 3. Remove the rear brake anti-lock sensor. NOTE: Remove all dirt from mounting surface and sensor to prevent contamination of rear axle lubrication. INSTALLATION Clean and inspect the rear brake anti-lock sensor. 1. Clean the axle mounting surface. Use care not to get dirt in the rear axle housing. 2. Inspect and clean the magnetized rear brake anti-lock sensor pole piece. 3. Inspect the rear anti-lock brake control o-ring for damage. Replace if necessary. 4. Lightly lubricate the rear anti-lock brake control o-ring with engine oil. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 7591 Rear Brake And Anti-Lock Sensor Install the rear brake anti-lock sensor. 1. Position the rear brake anti-lock sensor and install the rear brake anti-lock sensor bolt. NOTE: Do not apply force to the plastic rear brake anti-lock sensor connector. 2. Connect the electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure Brake Bleeding: Service and Repair Caliper Bleeding Procedure WARNING: ^ Brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. Wash hands thoroughly after handling. if brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: ^ Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. ^ Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: ^ When any part of the hydraulic system has been disconnected for repair or replacement, air may get in to the system and cause spongy brake pedal action. This requires the bleeding of the affected portions of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment Brake Bleeder. 1. Connect a clear waste line to the affected disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Open the bleeder screw and cycle the brake pedal 25 to 30 times or until no more air is seen at the waste line. Tighten Disc Brake Caliper Bleeder Screw 3. Tighten the disc brake caliper bleeder screw to proper specification. 4. Disconnect the waste line. 5. Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid, C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A, DOT 3. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7596 Brake Bleeding: Service and Repair Gravity Bleeding WARNING: ^ Brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. Wash hands thoroughly after handling. if brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: ^ Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. ^ Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: ^ When any part of the hydraulic system has been disconnected for repair or replacement, air may get in to the system and cause spongy brake pedal action. This requires the bleeding of the affected portions of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment Brake Bleeder. 1. Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A, DOT 3. 2. Bleed the rear disc brake calipers. a. Place a box end wrench on the RH disc brake caliper bleeder screw. b. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. c. Open the bleeder screw and leave open until clear bubble-free brake fluid flows. d. Repeat for LH rear disc brake caliper. 3. Tighten the rear disc brake caliper bleeder screws. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7597 4. Bleed the front disc brake calipers. a. Place a box end wrench on the RH front disc brake caliper bleeder screw. b. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. c. Open the bleeder screw and leave open until clear bubble-free brake fluid flows. d. Repeat for LH front disc brake caliper. 5. Tighten the front disc brake caliper bleeder screws. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7598 Brake Bleeding: Service and Repair Manual Bleeding WARNING: ^ Brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. Wash hands thoroughly after handling. if brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: ^ Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. ^ Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: ^ When any part of the hydraulic system has been disconnected for repair or replacement, air may get in to the system and cause spongy brake pedal action. This requires the bleeding of the affected portions of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment Brake Bleeder. 1. Place a box end wrench on the RH rear disc brake caliper bleeder screw. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Have an assistant pump the brake pedal 10 times and then hold firm pressure on the brake pedal. 3. Loosen the RH rear disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH rear disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 4. Tighten the RH rear disc brake caliper bleeder screw. 5. Repeat steps 1, 2, 3, and 4 for the LH rear disc brake caliper. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7599 6. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 7. Have an assistant pump the brake pedal 10 times and then hold firm pressure on the brake pedal. 8. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH front disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 9. Tighten the RH front disc brake caliper bleeder screw. 10. Repeat steps 6, 7, 8, and 9 for the LH front disc brake caliper bleeder screw. 11. If necessary, bleed the brake master cylinder. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7600 Brake Bleeding: Service and Repair Master Cylinder Bleeding WARNING: ^ brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: ^ Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. ^ Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: ^ When any part of the hydraulic system has been disconnected for repair or replacement, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment Brake Bleeder. 1. Support the brake master cylinder body in a vise and fill the brake master cylinder reservoir with specified brake fluid. ^ Use High Performance DOT 3 Brake Fluid C6AZ-19S42-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A, DOT 3. 2. Install plugs in the front and rear brake outlet ports. Bleed the front brake system first. Loosen Plug 3. Loosen the plug in the front outlet port and slowly depress the primary piston. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7601 Tighten Plug 4. Tighten the plug in the front outlet port and release the primary piston. 5. Repeat this procedure until clear, bubble-free brake fluid flows. 6. Repeat steps 3, 4, and 5 for the rear outlet port with the front outlet port plugged. 7. Tighten the plugs and try to depress the primary piston. The piston will not depress if all the air is out of the system. 8. Install the brake master cylinder filler cap and install the brake master cylinder in the vehicle. 9. Bleed the system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7602 Brake Bleeding: Service and Repair Caliper Bleeding Procedure WARNING: ^ Brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. Wash hands thoroughly after handling. if brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: ^ Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. ^ Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: ^ When any part of the hydraulic system has been disconnected for repair or replacement, air may get in to the system and cause spongy brake pedal action. This requires the bleeding of the affected portions of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment Brake Bleeder. 1. Connect a clear waste line to the affected disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Open the bleeder screw and cycle the brake pedal 25 to 30 times or until no more air is seen at the waste line. Tighten Disc Brake Caliper Bleeder Screw 3. Tighten the disc brake caliper bleeder screw to proper specification. 4. Disconnect the waste line. 5. Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid, C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A, DOT 3. Gravity Bleeding WARNING: ^ Brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. Wash hands thoroughly after handling. if brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: ^ Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7603 ^ Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: ^ When any part of the hydraulic system has been disconnected for repair or replacement, air may get in to the system and cause spongy brake pedal action. This requires the bleeding of the affected portions of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment Brake Bleeder. 1. Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A, DOT 3. 2. Bleed the rear disc brake calipers. a. Place a box end wrench on the RH disc brake caliper bleeder screw. b. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. c. Open the bleeder screw and leave open until clear bubble-free brake fluid flows. d. Repeat for LH rear disc brake caliper. 3. Tighten the rear disc brake caliper bleeder screws. 4. Bleed the front disc brake calipers. a. Place a box end wrench on the RH front disc brake caliper bleeder screw. b. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. c. Open the bleeder screw and leave open until clear bubble-free brake fluid flows. d. Repeat for LH front disc brake caliper. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7604 5. Tighten the front disc brake caliper bleeder screws. Manual Bleeding WARNING: ^ Brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. Wash hands thoroughly after handling. if brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: ^ Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. ^ Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: ^ When any part of the hydraulic system has been disconnected for repair or replacement, air may get in to the system and cause spongy brake pedal action. This requires the bleeding of the affected portions of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment Brake Bleeder. 1. Place a box end wrench on the RH rear disc brake caliper bleeder screw. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Have an assistant pump the brake pedal 10 times and then hold firm pressure on the brake pedal. 3. Loosen the RH rear disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH rear disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 4. Tighten the RH rear disc brake caliper bleeder screw. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7605 5. Repeat steps 1, 2, 3, and 4 for the LH rear disc brake caliper. 6. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 7. Have an assistant pump the brake pedal 10 times and then hold firm pressure on the brake pedal. 8. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH front disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 9. Tighten the RH front disc brake caliper bleeder screw. 10. Repeat steps 6, 7, 8, and 9 for the LH front disc brake caliper bleeder screw. 11. If necessary, bleed the brake master cylinder. Master Cylinder Bleeding WARNING: ^ brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: ^ Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. ^ Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: ^ When any part of the hydraulic system has been disconnected for repair or replacement, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment Brake Bleeder. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7606 1. Support the brake master cylinder body in a vise and fill the brake master cylinder reservoir with specified brake fluid. ^ Use High Performance DOT 3 Brake Fluid C6AZ-19S42-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A, DOT 3. 2. Install plugs in the front and rear brake outlet ports. Bleed the front brake system first. Loosen Plug 3. Loosen the plug in the front outlet port and slowly depress the primary piston. Tighten Plug 4. Tighten the plug in the front outlet port and release the primary piston. 5. Repeat this procedure until clear, bubble-free brake fluid flows. 6. Repeat steps 3, 4, and 5 for the rear outlet port with the front outlet port plugged. 7. Tighten the plugs and try to depress the primary piston. The piston will not depress if all the air is out of the system. 8. Install the brake master cylinder filler cap and install the brake master cylinder in the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7607 9. Bleed the system. Pressure Bleeding WARNING: ^ Brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. Wash hands thoroughly after handling. if brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: ^ Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. ^ Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: ^ When any part of the hydraulic system has been disconnected for repair or replacement, air may get in to the system and cause spongy brake pedal action. This requires the bleeding of the affected portions of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment Brake Bleeder. ^ Bleed the longest line first. Be sure the bleeder tank contains enough specified brake fluid to complete the bleeding operation. 1. Clean all dirt from and remove the (A) brake master cylinder filler cap and fill the (B) brake master cylinder reservoir with the specified brake fluid. 2. Install Brake Bleeder to the brake master cylinder reservoir and attach the bleeder tank hose to the fitting on the adapter. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers of pressure bleeding equipment. Follow the instructions of the manufacturer when installing the adapter. 3. Place a box end wrench on the RH rear disc brake caliper bleeder screw. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 4. Open the valve on the bleeder tank. 5. Open the rear disc brake caliper bleeder screw. Leave open until clear, bubble-free brake fluid flows, then close rear disc brake caliper bleeder screw and remove the rubber hose. 6. Continue bleeding the rest of the system, going in order from the LH rear disc brake caliper to the RH front disc brake caliper ending with the LH front disc brake caliper. 7. Close the bleeder tank valve and remove the tank hose from the adapter and remove the adapter. 8. Fill the (A) brake master cylinder reservoir and install the (B) brake master cylinder filler cap. 4 Wheel Anti-Lock Brakes (4WABS) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7608 WARNING: ^ Brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. Wash hands thoroughly after handling. if brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. get medical attention immediately. CAUTION: ^ Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. ^ Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: ^ When any part of the hydraulic system has been disconnected for repair or replacement, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment Brake Bleeder. ^ This procedure only needs to be performed if the 4 Wheel Anti-lock Brake System (4WABS) Hydraulic Control Unit (HCU) has been replaced. ^ One conventional pressure bleed cycle consists of advancing the brake pedal to its depressed position, opening the rear disc brake caliper bleeder screw, allowing fluid to be released into the waste container, closing the rear disc brake caliper bleeder screw and releasing the brake pedal to its full upright position. ^ Performing the New Generation Star (NGS) program routine drives entrapped air from the otherwise inaccessible lower section of the 4WABS valve into the upper sections (accessible by bleeding the brakes). Subsequent bleedings remove the air from the system. ^ Add recommended brake fluid as necessary throughout the procedure. PROCEDURE 1. Connect a clear waste line to the RH rear disc brake caliper bleeder screw and the other end in a container partially filled with recommended brake fluid. 2. With the RH rear disc brake caliper bleeder screw open, cycle the brake pedal until no more air is seen in the waste line. 3. Close the RH rear disc brake caliper bleeder screw and disconnect the waste line. 4. Repeat steps 1, 2, and 3 for the LH rear disc brake caliper bleeder screw, RH front disc brake caliper bleeder screw, and the LH front disc brake caliper bleeder screw. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7609 Connect Cable Adapter 5. Connect the (A) NGS DCL cable adapter into the (B) vehicle data link connector (DLC). 6. Select VEHICLE AND ENGINE SELECTION and press trigger to start the NGS. 7. Select SELECT NEW VEHICLE YEAR AND MODEL and press trigger to start the NGS. 8. Select the appropriate vehicle year application and press trigger to start the NGS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7610 9. Scroll down to the appropriate vehicle application and highlight and trigger to start the NGS. 10. The NGS will prompt you to verify correct application. Trigger the NGS if correct. 11. Select DIAGNOSTIC DATA LINK and press trigger to start the NGS. 12. Follow the NGS prompt PRESS TRIGGER TO CONTINUE or PRESS CANCEL TO BYPASS. 13. Select ABS ANTI-LOCK BRAKE MODULE and press trigger to start the NGS. 14. Select FUNCTION TESTS and press trigger to start the NGS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7611 15. Select SERVICE BLEED FUNCTION and press trigger to start the NGS. 16. Select PRESS TRIGGER TO BEGIN. NOTE: The brake pedal should be depressed while this procedure is functioning. Perform at least five service bleed procedures. 17. Repeat conventional bleed procedure as outlined in steps 1 through 4. 18. If brake pedal feels spongy, repeat NGS service bleed procedure as outlined in steps 5 through 16 and repeat conventional bleed steps 1 through 4. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications Brake Pedal Assy: Specifications TIGHTENING SPECIFICATIONS Pedal Bracket Nuts And Bolt ..................................................................................................................................................... 22-28 Nm (17-20 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 7615 Brake Pedal Assy: Service and Repair Disconnect Brake Master Cylinder Push Rod REMOVAL 1. Disconnect the brake master cylinder push rod. a. Remove the self-locking pin. b. Separate the (A) brake on off (BOO) switch from the (B) brake master cylinder push rod. c. Remove the brake master cylinder push rod spacer. d. Remove the brake master cylinder push rod bushing. Remove Brake Pedal Assembly 2. Remove the one brake pedal bracket bolt and the four brake pedal bracket nuts and remove the brake pedal assembly. CAUTION: Support the brake master cylinder and power brake booster in the engine compartment. Install Brake Pedal Assembly INSTALLATION To install, reverse the removal procedure, noting the following: ^ Tighten pedal nuts and bolt to 22-28 Nm (17-20 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Testing and Inspection Brake Warning Indicator: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Front Brake Caliper: Specifications Anchor Plate Bolts 125-169 ft.lb Caliper Bleeder Screws 11-14 ft.lb Caliper Bolts 21-26 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Front > Page 7624 Brake Caliper: Specifications Bore Diameter 2.01 in Adaptor Bolts 70 ft.lb Caliper Bleeder Screws 12-18 ft.lb Caliper Bolts 20 ft.lb Caliper Flow Bolts 23-29 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Page 7625 Brake Caliper: Diagrams (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service Precautions > Customer Safety Information Brake Caliper: Customer Safety Information WARNING: Always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or front disc brake rotor that contacts the wheel. Installing wheels without proper metal to metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and could allow the wheel to come off while the vehicle is in motion, causing loss of control. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service Precautions > Customer Safety Information > Page 7628 Brake Caliper: Technician Safety Information WARNING: ^ Asbestos fiber dust may be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies should be cleaned using a vacuum cleaner recommended for use with asbestos fibers such as brake/clutch/service vacuum. The bag must be labeled per osha instructions, sealed, and the trash hauler notified as to the bag's contents. If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government-approved toxic dust purifying respirators. Grinding or sanding brake linings, pads, rotors, drums or clutch facings should be performed using properly exhaust-ventilated equipment. Occupational Health And Safety Act (OSHA) requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians performing brake or clutch repair should be present in the area. ^ The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. ^ Brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. Wash hands thoroughly after handling. if brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. ^ Always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or front disc brake rotor that contacts the wheel. Installing wheels without proper metal to metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and could allow the wheel to come off while the vehicle is in motion, causing loss of control. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service Precautions > Customer Safety Information > Page 7629 Brake Caliper: Vehicle Damage Warnings WARNING: ^ Always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or front disc brake rotor that contacts the wheel. Installing wheels without proper metal to metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and could allow the wheel to come off while the vehicle is in motion, causing loss of control. ^ The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. CAUTION: ^ Do not use heat to loosen a seized lug nut. Heat can damage the wheel and the wheel bearings. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service Precautions > Page 7630 Brake Caliper: Description and Operation The front disc brake caliper: ^ Is a pin slider, dual piston type. ^ Has two caliper pistons. ^ The caliper housing has a fluid inlet at the center of the bore. A square section seal fitted into an annular groove in the caliper cylinder bore seals against hydraulic pressure, while rubber boots seal the caliper pistons and caliper bore from contamination. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Anchor Plate Brake Caliper: Service and Repair Anchor Plate REMOVAL 1. Remove the brake pads. 2. Remove the front disc brake caliper anchor plate. a. Remove the two front disc brake caliper anchor plate bolts. b. Remove the front disc brake caliper anchor plates. Install Front Disc Brake Caliper Anchor Plate INSTALLATION 1. Install the front disc brake caliper anchor plate. a. Position the front disc brake caliper anchor plate. b. Install the front disc brake caliper anchor plate bolts. 2. Install the brake pads. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 7633 Brake Caliper: Service and Repair Bleeding WARNING: ^ Brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. Wash hands thoroughly after handling. if brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: ^ Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. ^ Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: ^ When any part of the hydraulic system has been disconnected for repair or replacement, air may get in to the system and cause spongy brake pedal action. This requires the bleeding of the affected portions of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment Brake Bleeder. 1. Connect a clear waste line to the affected disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Open the bleeder screw and cycle the brake pedal 25 to 30 times or until no more air is seen at the waste line. Tighten Disc Brake Caliper Bleeder Screw 3. Tighten the disc brake caliper bleeder screw to proper specification. 4. Disconnect the waste line. 5. Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid, C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A, DOT 3. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 7634 Brake Caliper: Service and Repair Front Overhaul DISASSEMBLY 1. Remove the front disc brake caliper. 2. Drain the remaining brake fluid from the front disc brake caliper. 3. Secure the disc brake caliper in a vise. 4. Remove the caliper pistons. a. Place a block of wood between the caliper bridge and the caliper pistons. b. Apply low air pressure to the fluid port in the disc brake caliper. c. Force out the caliper pistons to the block of wood. d. Remove the block of wood and the caliper pistons. 5. Remove and discard the piston seals and boots. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 7635 (Part 2 Of 2) 6. If the front disc brake caliper is leaking, replace the piston seals. If the cylinder bores are excessively scored or corroded, replace the front disc brake caliper. NOTE: Do not hone the cylinder bores. Pistons are not available for honed cylinder bores. CAUTION: ^ Never reuse piston seals and dust boots. ^ Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended period of time. ASSEMBLY 1. Lubricate the piston boot, caliper piston, piston seal, and cylinder bores with High Performance Brake Fluid C6AZ- 19542-AB or DOT3 equivalent meeting Ford specification ESA-M6C25-A. Install Caliper Pistons 2. Install the caliper pistons. a. Install the piston seal. b. Install the piston boot on the caliper piston. c. Insert the caliper piston. CAUTION: Be careful not to damage or dislodge the piston seal. d. Press the caliper piston into the cylinder bore being careful not to cock the caliper piston. 3. Install the front disc brake caliper. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 7636 Removal and Installation WARNING: Asbestos fiber dust may be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies should be cleaned using a vacuum cleaner recommended for use with asbestos fibers such as brake/clutch/service vacuum. The bag must be labeled per osha instructions, sealed, and the trash hauler notified as to the bag's contents. If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government-approved toxic dust purifying respirators. Grinding or sanding brake linings, pads, rotors, drums or clutch facings should be performed using properly exhaust-ventilated equipment. Occupational Health And Safety Act (OSHA) requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians performing brake or clutch repair should be present in the area. REMOVAL 1. Loosen the lug nuts. a. Remove the center cap. b. With the weight of the vehicle on the wheels, CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and the wheel bearings. 2. Raise and support the vehicle. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. 3. Remove the wheel and tire assembly. a. Remove the lug nuts. b. Remove the wheel and tire assembly. 4. Inspect the brake shoes and linings for wear or contamination. NOTE: Replace the lining if worn to or past specifications. Replace the brake shoes and linings in complete axle sets. 5. Disconnect the front brake hose. a. Remove the front brake hose bolt. b. Remove the copper washers. Plug the front brake hose. c. Disconnect the front brake hose. WARNING: Brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. Wash hands thoroughly after handling. if brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. 6. Remove the disc brake caliper. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 7637 a. Remove the two caliper bolts. b. Lift the front disc brake caliper off the front disc brake caliper anchor plate. 7. Measure the front disc brake rotor thickness. ^ Replace the front disc brake rotor if not within specifications. 8. Inspect the disc brake caliper for leaks. ^ If leaks are found, disassembly is required. INSTALLATION 1. Install the front disc brake caliper and bolts; torque to 28-36 Nm (21-26 ft. lbs.). 2. 2. Install the front brake hose; torque banjo bolt to 30-40 Nm (23-29 ft. lbs.). ^ Use new copper washers to connect the front brake hose. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 7638 3. Bleed the front disc brake caliper. See: Bleeding 4. Clean the wheel hub mounting surface. WARNING: Always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or front disc brake rotor that contacts the wheel. Installing wheels without proper metal to metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and could allow the wheel to come off while the vehicle is in motion, causing loss of control. Install Tire And Wheel Assembly 5. Install the tire and wheel assembly. 6. Inspect the brake operation. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 7639 Brake Caliper: Service and Repair Rear Adapter REMOVAL 1. Disconnect the parking brake cable and conduit. 2. Remove the parking brake shoe and lining. 3. Remove the axle shaft. Refer to Transmission and Drivtrain. Remove Rear Wheel Disc Brake Adapter 4. Remove the rear wheel disc brake adapter. a. Remove the bolts. b. Remove the rear wheel disc brake adapter. Install Rear Wheel Disc Brake Adapter INSTALLATION 1. To install, reverse the removal procedure. Overhaul DISASSEMBLY 1. Remove the rear disc brake caliper. CAUTION: Do not remove the caliper guide pins or caliper guide pin boots unless a problem is suspected. The caliper guide pins are meant to be sealed for life and are not repairable. At the time of publication there are no approved materials or procedures to lubricate the caliper slide pins. Other greases may swell the guide pin boots resulting in contamination and accelerated corrosion or wear of the caliper guide pin mechanism. 2. Drain the remaining brake fluid from the rear disc brake caliper. 3. Secure the rear disc brake caliper in a vise. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 7640 Remove Caliper Piston 4. Remove the caliper piston. a. Place a block of wood between the caliper bridge and the caliper piston. b. Apply low air pressure to the fluid port in the rear disc brake caliper. c. Force out the caliper piston to the block of wood. d. Remove the block of wood and the caliper piston. Remove Piston Seal And Dust Boot 5. Remove and discard the piston seal and dust boot. NOTE: Do not hone the cylinder bore. Pistons are not available for honed cylinder bores. If the rear disc brake caliper cylinder bore is excessively scored or corroded, replace the rear disc brake caliper. CAUTION: ^ Never reuse the piston seal or dust boot. ^ Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended period of time. ASSEMBLY 1. Lubricate the following with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A, DOT 3. a. Cylinder bore. b. Piston seal. c. Caliper piston. d. Piston dust boot. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 7641 2. Install the piston seal. 3. Use Driver Handle and Piston Dust Seal Replacer to install the piston dust boot. 4. Install the caliper piston. CAUTION: Be careful not to damage or dislodge the piston seal. 5. Install the rear disc brake caliper. Removal and Installation WARNING: Asbestos fiber dust may be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies should be cleaned using a vacuum cleaner recommended for use with asbestos fibers such as brake/clutch/service vacuum. The bag must be labeled per osha instructions, sealed, and the trash hauler notified as to the bag's contents. If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government-approved toxic dust purifying respirators. Grinding or sanding brake linings, pads, rotors, drums or clutch facings should be performed using properly exhaust-ventilated equipment. Occupational Health And Safety Act (OSHA) requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians performing brake or clutch repair should be present in the area. REMOVAL 1. Loosen the lug nuts. a. Remove the center cap. b. With the weight of the vehicle on the wheels, loosen the lug nuts. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and the wheel bearings. 2. Raise and support the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 7642 WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. 3. Remove the wheel and tire assembly. a. Remove the lug nuts. b. Remove the wheel and tire assembly. Inspect Lining 4. Inspect the brake shoes and linings for wear or contamination. a. Replace the lining if worn to or past specification. NOTE: Replace the brake shoes and linings in complete axle sets. 5. Disconnect the brake hose. a. Remove the brake hose bolt. b. Remove the copper washers and plug the brake hose. c. Disconnect the brake hose. WARNING: Brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. Wash hands thoroughly after handling. if brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Remove Rear Disc Brake Caliper 6. Remove the rear disc brake caliper. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 7643 a. Remove the bolts. b. Lift the rear disc brake caliper off the rear disc brake caliper anchor plate. CAUTION: Do not remove the caliper guide pins or caliper guide pin boots unless a problem is suspected. The caliper guide pins are meant to be sealed for life and are not repairable. At the time of publication there are no approved materials or procedures to lubricate the caliper guide pins. Other greases may swell the caliper guide pin boots resulting in contamination and accelerated corrosion or wear of the caliper guide pin mechanism. 7. Inspect the rear disc brake caliper for leaks. ^ If leaks are found, disassembly is required. Measure Rear Disc Brake Rotor Thickness 8. Measure the rear disc brake rotor thickness. ^ Replace the rear disc brake rotor if not within specification. Install Rear Disc Brake Caliper INSTALLATION 1. Install the front disc brake caliper and bolts; torque to 27 Nm (20 ft. lbs.). CAUTION: To prevent interference with rear disc brake caliper operation, install only the correct caliper bolt. NOTE: ^ Make sure the stainless steel shoe slippers are correctly positioned. Replace if worn or damaged. ^ Make sure the notches on the upper ends of the brake shoe and linings are seated over the upper shoe slipper. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 7644 2. Install the front brake hose; torque banjo bolt to 30-40 Nm (23-29 ft. lbs.). ^ Use new copper washers to connect the brake hose. 3. Bleed the disc brake caliper. See: Bleeding 4. Clean the wheel hub mounting surface. WARNING: Always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or disc brake rotor that contacts the wheel. Installing wheels without proper metal to metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and come off while the vehicle is in motion, causing loss of control. Install Wheel And Tire Assembly 5. Install the wheel and tire assembly. a. Position the wheel and tire assembly. b. Install the lug nuts and snug to fully seat wheel and tire assembly, lower the vehicle. c. Tighten the lug nuts. d. Install the center cap. 6. Inspect the brake system for normal operation. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Brake and Rotor - Service Tips Brake Pad: Technical Service Bulletins Brake and Rotor - Service Tips Article No. 97-19-4 09/15/97 BRAKES - BRAKE AND ROTOR SERVICE TIPS FORD: 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-98 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1993-94 TOPAZ 1993-97 COUGAR 1993-98 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1994-98 MARK VIII 1995-98 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 AEROSTAR 1993-98 RANGER, VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION ISSUE: This TSB article is intended to give a technician information regarding brake repairs to help reduce unnecessary repairs. ACTION: Refer to the following list when performing brake repairs. ^ Where rotors are the causal part, linings should only be replaced if they are damaged, e.g., cracked, taper wear, heavily grooved, etc., or if specifically instructed in a TSB. ^ Where linings are the causal part, rotors should not be machined unless they are heavily grooved or if specifically instructed in a TSB. Other exceptions would include instances where the non-causal parts are found to be below minimum serviceable thickness or if the technician estimates that the parts will not last until the next service interval. Since these parts are classified as wear items (such as: linings, pads, rotors, and drums) replacement is not covered under warranty. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Front Brake Pad: Specifications Pad Minimum Thickness 0.125 in Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Front > Page 7651 Brake Pad: Specifications Lining Minimum Thickness 0.125 in Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service Precautions > Customer Safety Information Brake Pad: Customer Safety Information WARNING: Always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or front disc brake rotor that contacts the wheel. Installing wheels without proper metal to metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and could allow the wheel to come off while the vehicle is in motion, causing loss of control. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service Precautions > Customer Safety Information > Page 7654 Brake Pad: Technician Safety Information WARNING: ^ Asbestos fiber dust may be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies should be cleaned using a vacuum cleaner recommended for use with asbestos fibers such as brake/clutch/service vacuum. The bag must be labeled per osha instructions, sealed, and the trash hauler notified as to the bag's contents. If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government-approved toxic dust purifying respirators. Grinding or sanding brake linings, pads, rotors, drums or clutch facings should be performed using properly exhaust-ventilated equipment. Occupational Health And Safety Act (OSHA) requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians performing brake or clutch repair should be present in the area. ^ The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. ^ Brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. Wash hands thoroughly after handling. if brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. ^ Always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or front disc brake rotor that contacts the wheel. Installing wheels without proper metal to metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and could allow the wheel to come off while the vehicle is in motion, causing loss of control. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service Precautions > Customer Safety Information > Page 7655 Brake Pad: Vehicle Damage Warnings WARNING: ^ Always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or front disc brake rotor that contacts the wheel. Installing wheels without proper metal to metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and could allow the wheel to come off while the vehicle is in motion, causing loss of control. ^ The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. CAUTION: ^ Do not use heat to loosen a seized lug nut. Heat can damage the wheel and the wheel bearings. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service Precautions > Page 7656 Brake Pad: Description and Operation The brake pads are: ^ Contained within the front disc brake caliper anchor plate. ^ Held to the front disc brake caliper anchor plate abutments by disc brake anti-rattle clips. ^ Bolts to the front wheel knuckle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service Precautions > Page 7657 Brake Pad: Testing and Inspection 1. Inspect the brake pads for wear or contamination. 2. Replace the lining if worn to or past: ^ Front 3.00 mm (0.125 inch). ^ Rear 3.12 mm (0.125 inch). NOTE: Replace the brake pads in complete axle sets. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front Brake Pad: Service and Repair Front WARNING: Asbestos fiber dust may be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies should be cleaned using a vacuum cleaner recommended for use with asbestos fibers such as brake/clutch/service vacuum. The bag must be labeled per osha instructions, sealed, and the trash hauler notified as to the bag's contents. If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government-approved toxic dust purifying respirators. Grinding or sanding brake linings, pads, rotors, drums or clutch facings should be performed using properly exhaust-ventilated equipment. Occupational Health And Safety Act (OSHA) requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians performing brake or clutch repair should be present in the area. REMOVAL 1. Loosen the lug nuts. a. Remove the center cap. b. With the weight of the vehicle on the wheels, loosen the lug nuts. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and the wheel bearings. 2. Raise and support the vehicle. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. 3. Remove the wheel and tire assembly. a. Remove the lug nuts. b. Remove the wheel and tire assembly. Inspect Brake Lining 4. Inspect the brake pads for wear or contamination. NOTE: Replace the pads if worn to or past specifications. Replace the brake pads in complete axle sets. 5. Measure the front disc brake rotor thickness. ^ Replace the front disc brake rotor if not within specification. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 7660 6. Remove the front disc brake caliper. a. Remove the two caliper bolts. b. Lift the front disc brake caliper off the front disc brake caliper anchor plate. CAUTION: When removing the front disc brake caliper, never allow it to hang from a brake hose. Provide a suitable support. 7. Inspect the disc brake caliper for leaks. ^ If leaks are found, disassembly is required. 8. Remove the disc brake anti-rattle clips. a. Remove the brake pads. b. Remove the disc brake anti-rattle clips. INSTALLATION 1. Install the brake pads. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 7661 a. Install the disc brake anti-rattle clips. b. Install the brake pads. CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the front brake pad material. Do not install contaminated brake shoe and linings. 2. Install the front disc brake caliper and bolts; torque to 28-36 Nm (21-26 ft. lbs.). CAUTION: Use care not to damage the bleeder screw or front wheel disc brake shield. 3. Clean the wheel hub mounting surface. WARNING: Always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or front disc brake rotor that contacts the wheel. Installing wheels without proper metal to metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and could allow the wheel to come off while the vehicle is in motion, causing loss of control. 4. Install the tire and wheel assembly. 5. Inspect the brake operation. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 7662 Brake Pad: Service and Repair Rear WARNING: Asbestos fiber dust may be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies should be cleaned using a vacuum cleaner recommended for use with asbestos fibers such as brake/clutch/service vacuum. The bag must be labeled per osha instructions, sealed, and the trash hauler notified as to the bag's contents. If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government-approved toxic dust purifying respirators. Grinding or sanding brake linings, pads, rotors, drums or clutch facings should be performed using properly exhaust-ventilated equipment. Occupational Health And Safety Act (OSHA) requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians performing brake or clutch repair should be present in the area. REMOVAL 1. Remove the rear disc brake caliper. CAUTION: Do not allow the rear disc brake caliper to hang by the rear brake hose. Provide a suitable support. NOTE: When removing the rear disc brake caliper in this procedure, it is not necessary to disconnect the brake hose. Remove Rear Brake Shoe And Lining 2. Remove the rear brake pads. CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the rear brake pads. 3. Remove the shoe slippers. INSTALLATION 1. Install the shoe slippers. 2. Install the rear brake pads. CAUTION: The brake shoes and linings should be replaced in full axle sets only. Do not replace worn rear brake shoe and linings on only one side of the vehicle. NOTE: When installed, the locator notch on the brake shoe and lining will be located at the upper end of the rear disc brake caliper. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 7663 Install Rear Brake Caliper 3. Install the rear disc brake caliper and torque to 27 Nm (20 ft. lbs.). NOTE: Make sure the notches on the upper ends of the brake shoe and linings are seated over the upper shoe slipper. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Hub-Mount Brake Rotor Machining Equipment Technical Service Bulletin # 98-5A-5 Date: 980318 Hub-Mount Brake Rotor Machining Equipment Article No. 98-5A-5 03/18/98 ^ BRAKES - AVAILABILITY OF HUB-MOUNT BRAKE ROTOR MACHINING EQUIPMENT ^ BRAKE ROTOR MACHINING - AVAILABILITY OF HUB-MOUNT BRAKE ROTOR MACHINING EQUIPMENT FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-98 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1993-94 TOPAZ 1993-97 COUGAR 1993-98 CONTINENTAL, GRAND MARQUIS, MARK VIII, SABLE, TOWN CAR, TRACER 1995-98 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1993-98 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE: Hub-mount brake rotor machining equipment from Rotunda is now approved for warranty and service use. Brake roughness consists of one or more of the following symptoms while braking: ^ Steering wheel vibration/nibble ^ vibration ^ Brake pedal pulsation Brake roughness is caused by: ^ Uneven rotor wear known as Disc Thickness Variation (DTV). DTV is caused by excessive Lateral Run-Out (LRO) or overtorqued wheel lug nuts ^ Non-uniform lining transfer ACTION: Use Rotunda Hub-Mount Lathe / Pro-Cut (201-00002) to service vehicles with brake roughness. The hub-mount lathe removes DTV, lining transfer, and on-vehicle rotor LRO. The hub-mount lathe has the following advantages over caliper-mount lathes: ^ Improved rotor LRO and "dishing" tolerances ^ Ability to machine rear rotors on live axles, except for trucks with dual rear wheels ^ Easier set-up Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Hub-Mount Brake Rotor Machining Equipment > Page 7668 Refer to the Service Procedure for details. PART NUMBER PART NAME F6AZ-9L494-AA High Temperature Nickel Anti-Seize Lubricant OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-4-5 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 702300, 703000, 703400 Service Procedure 1. Verify concern. 2. Pre-checks to include: ^ Check OASIS and TSBs for vehicle-specific brake/vibration concerns ^ Visually inspect suspension bushings/ball joints ^ Visually inspect tire conditions and pressure ^ Check wheel bearing end-play 3. Remove wheel/tire. 4. Remove caliper. 5. For vehicles with two-piece hub/rotor: a. Mark rotor and wheel stud for proper indexing during reassembly. b. Remove rotor. NOTE: THE ROTOR MUST HAVE SUFFICIENT THICKNESS AFTER MACHINING TO BE OVER THE MINIMUM THICKNESS SPECIFICATION C 6. Measure rotor thickness and record measurement. Replace rotor if below the minimum thickness specification cast in the rotor. CAUTION: DO NOT USE ABRASIVE SANDING DISC SINCE IT WILL REMOVE METAL FROM MOUNTING SURFACES AND ADVERSELY AFFECT 7. Remove corrosion from wheel mounting surface, both rotor mounting surfaces, and hub mounting surface. A die grinder with a Scotchbrite(R) surfa 8. For vehicles with two-piece hub/rotor, reinstall rotor onto hub, aligning with marks from Step 5a. NOTE: READ THE ENTIRE OPERATING MANUAL AND VIEW THE VIDEO SHIPPED WITH THE LATHE BEFORE INSTALLING, OPERATING, OR SERVICING THE LATHE. 9. Machine rotors using the Rotunda Hub-Mount Brake Lathe / Pro-Cut (201-00002). a. Install hub adapter and silencer belt (where applicable). b. Install cutting lathe. NOTE: TOTAL INDICATED READING (TIR) TARGET IS 0.000 mm, MAXIMUM IS O.O6 mm (0.003"). c. Adjust lathe oscillation using a dial indicator. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Hub-Mount Brake Rotor Machining Equipment > Page 7669 NOTE: DEPTH OF CUT SHOULD BE BETWEEN 0.10 AND O.2O mm (0.004 AND 0.008"). LIGHTER CUTS WILL CAUSE THE BIT TO HEAT UP A d. Center cutting head, adjust cutting bits, install chip deflector. e. Machine rotor. f. Measure and record rotor thickness. NOTE: TARGET LRO IS 0.000 mm, MAXIMUM IS O.05 mm (0.002"). g. Install dial indicator, measure and record rotor LRO. Remove dial indicator. h. Remove lathe and silencer belt. 10. Remove metal shavings. 11. Remove the adapter. 12. For vehicles with two-piece hub/rotors: a. Remove rotor from hub. b. Remove metal shavings from hub and rotor mounting surfaces and from ABS sensors. c. Apply High Temperature Nickel Anti-Seize Lubricant (F6AZ-9L494-AA) to hub mounting surface to prevent future corrosion. d. Match marks on rotor and hub and assemble rotor to hub. 13. Install pads and calipers. NOTE: USING AN IMPACT TOOL WITHOUT AN ACCUTORO(R) SOCKET WILL LEAD TO UNEVENLY TORQUED LUG NUTS. THIS CAUSES ROTOR 14. Install wheels using impact guns equipped with Rotunda AccuTorq(R) sockets. Use a torque wrench on locking lug nuts. 15. Check brake operation before returning to customer. Support Telephone Numbers 1. Lathe Administration Support: (800) 768-8632 2. Pro-Cut Technical Support: (800) 543-6618 Reference list for Pro-Cut car labor operations: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Hub-Mount Brake Rotor Machining Equipment > Page 7670 ^ A = Aspire ^ B = Escort/Tracer ^ C = Probe ^ D = Contour/Mystique ^ E = Mustang ^ F = Taurus/Sable ^ G = Thunderbird/Cougar ^ H = Crown Victoria/Grand Marquis ^ I = Continental ^ J = Mark VIII ^ K = Town Car ^ L = Festiva ^ M = Tempo/Topaz Reference list for Pro-Cut light truck labor operations: ^ AA = Villager ^ AB = Windstar ^ AC = Aerostar 4X2 ^ AD = Aerostar 4X4 ^ AE = Ranger 4X2 ^ AF = Ranger 4X4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Hub-Mount Brake Rotor Machining Equipment > Page 7671 ^ AG = Explorer/Mountaineer 4X2 ^ AH = Explorer/Mountaineer 4X4 ^ AI = Econoline ^ AJ = F-250 HD/F-350 4X2 ^ AK = F-250 HD/F-350 4X4 ^ AL = F-Super Duty ^ AM = F-150/F-250 LD 4X2 ^ AN = F-150/F-250 LD 4X4 And Bronco ^ AO = Expedition/Navigator 4X2 ^ AP = Expedition/Navigator 4X4 ^ AQ = Super Duty F Series Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Hub-Mount Brake Rotor Machining Equipment > Page 7672 Brake Rotor/Disc: Technical Service Bulletins Brakes - Elimination Of Sanding Rotors And Drums Article No. 98-5A-11 03/18/98 BRAKES - ELIMINATION OF SANDING ROTORS AND DRUMS - SERVICE TIP FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1993-94 TOPAZ 1993-97 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VIII, SABLE, TOWN CAR, TRACER 1995-97 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 AEROSTAR, ECONOLINE, EXPLORER, F SUPER DUTY, F-150-350 SERIES, RANGER, VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: Repeat brake repairs have been performed due to sanding of brake rotors and drums. The sanding of rotors and drums may have been done in reference to a Service Manual or TSB article which prescribes sanding as a repair, however, sanding is neither an effective nor lasting repair for customer complaints of brake roughness or noise. ACTION: Machine brake rotors and drums instead of sanding to help reduce brake roughness caused by one of the following conditions: ^ Rotor thickness variation and lateral runout ^ Lining or foreign material build-up ^ Drum out-of-round NOTE: DO NOT MACHINE OR SAND ROTORS/DRUMS TO REDUCE OCCASIONAL BRAKE NOISE. IT IS NEITHER AN EFFECTIVE OR LASTING REPAIR. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-22-2 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Hub-Mount Brake Rotor Machining Equipment > Page 7673 Brake Rotor/Disc: Technical Service Bulletins Brake and Rotor - Service Tips Article No. 97-19-4 09/15/97 BRAKES - BRAKE AND ROTOR SERVICE TIPS FORD: 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-98 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1993-94 TOPAZ 1993-97 COUGAR 1993-98 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1994-98 MARK VIII 1995-98 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 AEROSTAR 1993-98 RANGER, VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION ISSUE: This TSB article is intended to give a technician information regarding brake repairs to help reduce unnecessary repairs. ACTION: Refer to the following list when performing brake repairs. ^ Where rotors are the causal part, linings should only be replaced if they are damaged, e.g., cracked, taper wear, heavily grooved, etc., or if specifically instructed in a TSB. ^ Where linings are the causal part, rotors should not be machined unless they are heavily grooved or if specifically instructed in a TSB. Other exceptions would include instances where the non-causal parts are found to be below minimum serviceable thickness or if the technician estimates that the parts will not last until the next service interval. Since these parts are classified as wear items (such as: linings, pads, rotors, and drums) replacement is not covered under warranty. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Hub-Mount Brake Rotor Machining Equipment > Page 7674 Brake Rotor/Disc: Technical Service Bulletins Brake Rotor - Incorrect Discard Thickness Specification Article No. 99-25-6 12/13/99 ^ BRAKES - INCORRECT ROTOR THICKNESS STAMPED ON ROTOR - F-150 4X2 ONLY ^ BRAKES - INCORRECT WORKSHOP MANUAL ROTOR DISCARD THICKNESS SPECIFICATION FORD: 1997-2000 EXPEDITION, F-150, F-250 LD LINCOLN: 1998-2000 NAVIGATOR ISSUE The 1997-2000 Workshop Manuals do not provide the correct and complete specification for rotor discard thickness. Additionally, some 4X2 F-150 rotors may have an incorrect rotor discard thickness stamped on them. Updated Information Per TSB 99-25-6 ACTION Refer to the Front and Rear Disc Rotor Discard Specification Charts for correct rotor discard specification. * SOME 4X2 F-150 ROTORS SHOW "24.7 mm" PRINTED ON THE ROTOR BACK SIDE. THIS IS AN ERROR, THESE CAN BE CUT TO 24.5 mm DISCARD THICKNESS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 390000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Brake Rotor/Disc Brake Rotor/Disc: Specifications Brake Rotor/Disc Minimum Rotor Thickness 1.09 in Minimum Thickness 0.472 in Runout 0.003 in Thickness Variation 0.013 in Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Brake Rotor/Disc > Page 7677 Brake Rotor/Disc: Specifications Disc Backing Plate TIGHTENING SPECIFICATIONS Front Rotor Shield Screws .................................................................................................................................................... 10-14 Nm (90-107 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service Precautions > Customer Safety Information Brake Rotor/Disc: Customer Safety Information WARNING: Always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or front disc brake rotor that contacts the wheel. Installing wheels without proper metal to metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and could allow the wheel to come off while the vehicle is in motion, causing loss of control. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service Precautions > Customer Safety Information > Page 7680 Brake Rotor/Disc: Technician Safety Information WARNING: ^ Asbestos fiber dust may be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies should be cleaned using a vacuum cleaner recommended for use with asbestos fibers such as brake/clutch/service vacuum. The bag must be labeled per osha instructions, sealed, and the trash hauler notified as to the bag's contents. If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government-approved toxic dust purifying respirators. Grinding or sanding brake linings, pads, rotors, drums or clutch facings should be performed using properly exhaust-ventilated equipment. Occupational Health And Safety Act (OSHA) requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians performing brake or clutch repair should be present in the area. ^ The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. ^ Brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. Wash hands thoroughly after handling. if brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. ^ Always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or front disc brake rotor that contacts the wheel. Installing wheels without proper metal to metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and could allow the wheel to come off while the vehicle is in motion, causing loss of control. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service Precautions > Customer Safety Information > Page 7681 Brake Rotor/Disc: Vehicle Damage Warnings WARNING: ^ Always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or front disc brake rotor that contacts the wheel. Installing wheels without proper metal to metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and could allow the wheel to come off while the vehicle is in motion, causing loss of control. ^ The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. CAUTION: ^ Do not use heat to loosen a seized lug nut. Heat can damage the wheel and the wheel bearings. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service Precautions > Page 7682 Brake Rotor/Disc: Description and Operation Rotor shield: ^ The front disc brake rotor shield protects the bearings and inboard surface of the front disc brake rotor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor/Disc Brake Rotor/Disc: Service and Repair Brake Rotor/Disc Front REMOVAL 1. Remove the front disc brake caliper anchor plate; refer to the procedure in this section. 2. On 4x4 vehicles, remove the front disc brake rotor. - If necessary, resurface the front disc brake rotor. 3. On 4x2 vehicles, remove the front disc brake hub and rotor as follows: 1. Remove the hub grease cap (1131). 2. Remove the cotter pin. 3. Remove the retainer nut. 4. Remove the spindle nut. 5. Remove the front wheel outer bearing retainer washer (1195). 6. Remove the outer front wheel bearing (1216). 7. Remove the front disc brake hub and rotor. 4. If necessary on 4x2 vehicles, resurface the front disc brake hub and rotor. 1. Remove the wheel hub grease seal (1190). 2. Remove the inner front wheel bearing. INSTALLATION 1. On 4x4 vehicles, position the front disc brake rotor. 1. Use Metal Brake Parts Cleaner F3AZ-19579-SA or equivalent and clean the front disc brake rotor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor/Disc > Page 7685 2. Position the front disc brake rotor. 2. On 4x2 vehicles, use Metal Brake Parts Cleaner F3AZ-1 9579-SA or equivalent to thoroughly clean and inspect the front wheel bearings and the front disc brake hub and rotor. 3. On 4x2 vehicles, lubricate the front wheel bearings. - Use Premium Long-Life Grease XG-1-C or-K or equivalent meeting Ford specification ESA-M1C198-A. 4. On 4x2 vehicles, install a new wheel hub grease seal. 1. Install the inner front wheel bearing. 2. Install a new wheel hub grease seal. 5. On 4x2 vehicles, install the front disc brake hub and rotor. 1. Position the front disc brake hub and rotor. 2. Install the outer front wheel bearing. 3. Install the front wheel outer bearing retainer washer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor/Disc > Page 7686 4. Install the spindle nut. Note: On 4x2 vehicles, the front disc brake hub and rotor should be rotated while adjusting front wheel bearing end play. 6. Tighten the spindle nut. Loosen Spindle Nut 7. Loosen the (A) spindle nut two turns. 8. Tighten the spindle nut while rotating the rotor counterclockwise. 9. Loosen the spindle nut Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor/Disc > Page 7687 10. Tighten the spindle nut. Rear REMOVAL 1. Remove the rear disc brake caliper. NOTE: When removing the rear disc brake caliper in this procedure it is not necessary to disconnect the brake hose. Remove Rear Disc Brake Rotor 2. Remove the rear disc brake rotor and axle hub channel. NOTE: If the rear disc brake rotor binds on the parking brake shoe and lining, remove the adjustment hole access plug and contract the parking brake shoe and lining. Measure Rear Disc Brake Rotor Tickness 3. Inspect the rear disc brake rotor. NOTE: Replace the rear disc brake rotor if not within 12 mm (0.472 inch). INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor/Disc > Page 7688 Brake Rotor/Disc: Service and Repair Disc Backing Plate Front Remove Front Disc Brake Rotor Shield REMOVAL 1. Remove the rotor. 2. Remove the wheel hub. 3. Remove the three rotor shield screws and shield. Install Front Disc Brake Rotor Shield Install Front Disc Brake Rotor Shield INSTALLATION To install, reverse the removal procedure noting the following: ^ Torque sheild bolts to 10-14 Nm (90-107 inch lbs.) Rear Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor/Disc > Page 7689 Remove Rear Wheel Disc Brake Shield REMOVAL 1. Remove the rear wheel disc brake adapter. 2. Remove the rear wheel disc brake shield, by drilling out the two rivets. INSTALLATION To install, reverse the removal procedure. Seal the rivet holes with Silicone Rubber D6AZ-19652-AA or equivalent meeting Ford specification ESB-M4G92-A. NOTE: Because the rear wheel disc brake shield is held in position by the four rear wheel disc brake adapter bolts, new rivets are not required. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Brakes - Elimination Of Sanding Rotors And Drums Brake Drum: Technical Service Bulletins Brakes - Elimination Of Sanding Rotors And Drums Article No. 98-5A-11 03/18/98 BRAKES - ELIMINATION OF SANDING ROTORS AND DRUMS - SERVICE TIP FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1993-94 TOPAZ 1993-97 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VIII, SABLE, TOWN CAR, TRACER 1995-97 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 AEROSTAR, ECONOLINE, EXPLORER, F SUPER DUTY, F-150-350 SERIES, RANGER, VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: Repeat brake repairs have been performed due to sanding of brake rotors and drums. The sanding of rotors and drums may have been done in reference to a Service Manual or TSB article which prescribes sanding as a repair, however, sanding is neither an effective nor lasting repair for customer complaints of brake roughness or noise. ACTION: Machine brake rotors and drums instead of sanding to help reduce brake roughness caused by one of the following conditions: ^ Rotor thickness variation and lateral runout ^ Lining or foreign material build-up ^ Drum out-of-round NOTE: DO NOT MACHINE OR SAND ROTORS/DRUMS TO REDUCE OCCASIONAL BRAKE NOISE. IT IS NEITHER AN EFFECTIVE OR LASTING REPAIR. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-22-2 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure Brake Bleeding: Service and Repair Caliper Bleeding Procedure WARNING: ^ Brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. Wash hands thoroughly after handling. if brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: ^ Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. ^ Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: ^ When any part of the hydraulic system has been disconnected for repair or replacement, air may get in to the system and cause spongy brake pedal action. This requires the bleeding of the affected portions of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment Brake Bleeder. 1. Connect a clear waste line to the affected disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Open the bleeder screw and cycle the brake pedal 25 to 30 times or until no more air is seen at the waste line. Tighten Disc Brake Caliper Bleeder Screw 3. Tighten the disc brake caliper bleeder screw to proper specification. 4. Disconnect the waste line. 5. Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid, C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A, DOT 3. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7700 Brake Bleeding: Service and Repair Gravity Bleeding WARNING: ^ Brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. Wash hands thoroughly after handling. if brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: ^ Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. ^ Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: ^ When any part of the hydraulic system has been disconnected for repair or replacement, air may get in to the system and cause spongy brake pedal action. This requires the bleeding of the affected portions of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment Brake Bleeder. 1. Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A, DOT 3. 2. Bleed the rear disc brake calipers. a. Place a box end wrench on the RH disc brake caliper bleeder screw. b. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. c. Open the bleeder screw and leave open until clear bubble-free brake fluid flows. d. Repeat for LH rear disc brake caliper. 3. Tighten the rear disc brake caliper bleeder screws. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7701 4. Bleed the front disc brake calipers. a. Place a box end wrench on the RH front disc brake caliper bleeder screw. b. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. c. Open the bleeder screw and leave open until clear bubble-free brake fluid flows. d. Repeat for LH front disc brake caliper. 5. Tighten the front disc brake caliper bleeder screws. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7702 Brake Bleeding: Service and Repair Manual Bleeding WARNING: ^ Brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. Wash hands thoroughly after handling. if brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: ^ Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. ^ Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: ^ When any part of the hydraulic system has been disconnected for repair or replacement, air may get in to the system and cause spongy brake pedal action. This requires the bleeding of the affected portions of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment Brake Bleeder. 1. Place a box end wrench on the RH rear disc brake caliper bleeder screw. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Have an assistant pump the brake pedal 10 times and then hold firm pressure on the brake pedal. 3. Loosen the RH rear disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH rear disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 4. Tighten the RH rear disc brake caliper bleeder screw. 5. Repeat steps 1, 2, 3, and 4 for the LH rear disc brake caliper. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7703 6. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 7. Have an assistant pump the brake pedal 10 times and then hold firm pressure on the brake pedal. 8. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH front disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 9. Tighten the RH front disc brake caliper bleeder screw. 10. Repeat steps 6, 7, 8, and 9 for the LH front disc brake caliper bleeder screw. 11. If necessary, bleed the brake master cylinder. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7704 Brake Bleeding: Service and Repair Master Cylinder Bleeding WARNING: ^ brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: ^ Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. ^ Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: ^ When any part of the hydraulic system has been disconnected for repair or replacement, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment Brake Bleeder. 1. Support the brake master cylinder body in a vise and fill the brake master cylinder reservoir with specified brake fluid. ^ Use High Performance DOT 3 Brake Fluid C6AZ-19S42-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A, DOT 3. 2. Install plugs in the front and rear brake outlet ports. Bleed the front brake system first. Loosen Plug 3. Loosen the plug in the front outlet port and slowly depress the primary piston. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7705 Tighten Plug 4. Tighten the plug in the front outlet port and release the primary piston. 5. Repeat this procedure until clear, bubble-free brake fluid flows. 6. Repeat steps 3, 4, and 5 for the rear outlet port with the front outlet port plugged. 7. Tighten the plugs and try to depress the primary piston. The piston will not depress if all the air is out of the system. 8. Install the brake master cylinder filler cap and install the brake master cylinder in the vehicle. 9. Bleed the system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7706 Brake Bleeding: Service and Repair Caliper Bleeding Procedure WARNING: ^ Brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. Wash hands thoroughly after handling. if brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: ^ Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. ^ Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: ^ When any part of the hydraulic system has been disconnected for repair or replacement, air may get in to the system and cause spongy brake pedal action. This requires the bleeding of the affected portions of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment Brake Bleeder. 1. Connect a clear waste line to the affected disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Open the bleeder screw and cycle the brake pedal 25 to 30 times or until no more air is seen at the waste line. Tighten Disc Brake Caliper Bleeder Screw 3. Tighten the disc brake caliper bleeder screw to proper specification. 4. Disconnect the waste line. 5. Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid, C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A, DOT 3. Gravity Bleeding WARNING: ^ Brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. Wash hands thoroughly after handling. if brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: ^ Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7707 ^ Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: ^ When any part of the hydraulic system has been disconnected for repair or replacement, air may get in to the system and cause spongy brake pedal action. This requires the bleeding of the affected portions of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment Brake Bleeder. 1. Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A, DOT 3. 2. Bleed the rear disc brake calipers. a. Place a box end wrench on the RH disc brake caliper bleeder screw. b. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. c. Open the bleeder screw and leave open until clear bubble-free brake fluid flows. d. Repeat for LH rear disc brake caliper. 3. Tighten the rear disc brake caliper bleeder screws. 4. Bleed the front disc brake calipers. a. Place a box end wrench on the RH front disc brake caliper bleeder screw. b. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. c. Open the bleeder screw and leave open until clear bubble-free brake fluid flows. d. Repeat for LH front disc brake caliper. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7708 5. Tighten the front disc brake caliper bleeder screws. Manual Bleeding WARNING: ^ Brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. Wash hands thoroughly after handling. if brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: ^ Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. ^ Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: ^ When any part of the hydraulic system has been disconnected for repair or replacement, air may get in to the system and cause spongy brake pedal action. This requires the bleeding of the affected portions of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment Brake Bleeder. 1. Place a box end wrench on the RH rear disc brake caliper bleeder screw. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Have an assistant pump the brake pedal 10 times and then hold firm pressure on the brake pedal. 3. Loosen the RH rear disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH rear disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 4. Tighten the RH rear disc brake caliper bleeder screw. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7709 5. Repeat steps 1, 2, 3, and 4 for the LH rear disc brake caliper. 6. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 7. Have an assistant pump the brake pedal 10 times and then hold firm pressure on the brake pedal. 8. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH front disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 9. Tighten the RH front disc brake caliper bleeder screw. 10. Repeat steps 6, 7, 8, and 9 for the LH front disc brake caliper bleeder screw. 11. If necessary, bleed the brake master cylinder. Master Cylinder Bleeding WARNING: ^ brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: ^ Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. ^ Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: ^ When any part of the hydraulic system has been disconnected for repair or replacement, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment Brake Bleeder. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7710 1. Support the brake master cylinder body in a vise and fill the brake master cylinder reservoir with specified brake fluid. ^ Use High Performance DOT 3 Brake Fluid C6AZ-19S42-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A, DOT 3. 2. Install plugs in the front and rear brake outlet ports. Bleed the front brake system first. Loosen Plug 3. Loosen the plug in the front outlet port and slowly depress the primary piston. Tighten Plug 4. Tighten the plug in the front outlet port and release the primary piston. 5. Repeat this procedure until clear, bubble-free brake fluid flows. 6. Repeat steps 3, 4, and 5 for the rear outlet port with the front outlet port plugged. 7. Tighten the plugs and try to depress the primary piston. The piston will not depress if all the air is out of the system. 8. Install the brake master cylinder filler cap and install the brake master cylinder in the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7711 9. Bleed the system. Pressure Bleeding WARNING: ^ Brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. Wash hands thoroughly after handling. if brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: ^ Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. ^ Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: ^ When any part of the hydraulic system has been disconnected for repair or replacement, air may get in to the system and cause spongy brake pedal action. This requires the bleeding of the affected portions of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment Brake Bleeder. ^ Bleed the longest line first. Be sure the bleeder tank contains enough specified brake fluid to complete the bleeding operation. 1. Clean all dirt from and remove the (A) brake master cylinder filler cap and fill the (B) brake master cylinder reservoir with the specified brake fluid. 2. Install Brake Bleeder to the brake master cylinder reservoir and attach the bleeder tank hose to the fitting on the adapter. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers of pressure bleeding equipment. Follow the instructions of the manufacturer when installing the adapter. 3. Place a box end wrench on the RH rear disc brake caliper bleeder screw. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 4. Open the valve on the bleeder tank. 5. Open the rear disc brake caliper bleeder screw. Leave open until clear, bubble-free brake fluid flows, then close rear disc brake caliper bleeder screw and remove the rubber hose. 6. Continue bleeding the rest of the system, going in order from the LH rear disc brake caliper to the RH front disc brake caliper ending with the LH front disc brake caliper. 7. Close the bleeder tank valve and remove the tank hose from the adapter and remove the adapter. 8. Fill the (A) brake master cylinder reservoir and install the (B) brake master cylinder filler cap. 4 Wheel Anti-Lock Brakes (4WABS) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7712 WARNING: ^ Brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. Wash hands thoroughly after handling. if brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. get medical attention immediately. CAUTION: ^ Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. ^ Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: ^ When any part of the hydraulic system has been disconnected for repair or replacement, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment Brake Bleeder. ^ This procedure only needs to be performed if the 4 Wheel Anti-lock Brake System (4WABS) Hydraulic Control Unit (HCU) has been replaced. ^ One conventional pressure bleed cycle consists of advancing the brake pedal to its depressed position, opening the rear disc brake caliper bleeder screw, allowing fluid to be released into the waste container, closing the rear disc brake caliper bleeder screw and releasing the brake pedal to its full upright position. ^ Performing the New Generation Star (NGS) program routine drives entrapped air from the otherwise inaccessible lower section of the 4WABS valve into the upper sections (accessible by bleeding the brakes). Subsequent bleedings remove the air from the system. ^ Add recommended brake fluid as necessary throughout the procedure. PROCEDURE 1. Connect a clear waste line to the RH rear disc brake caliper bleeder screw and the other end in a container partially filled with recommended brake fluid. 2. With the RH rear disc brake caliper bleeder screw open, cycle the brake pedal until no more air is seen in the waste line. 3. Close the RH rear disc brake caliper bleeder screw and disconnect the waste line. 4. Repeat steps 1, 2, and 3 for the LH rear disc brake caliper bleeder screw, RH front disc brake caliper bleeder screw, and the LH front disc brake caliper bleeder screw. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7713 Connect Cable Adapter 5. Connect the (A) NGS DCL cable adapter into the (B) vehicle data link connector (DLC). 6. Select VEHICLE AND ENGINE SELECTION and press trigger to start the NGS. 7. Select SELECT NEW VEHICLE YEAR AND MODEL and press trigger to start the NGS. 8. Select the appropriate vehicle year application and press trigger to start the NGS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7714 9. Scroll down to the appropriate vehicle application and highlight and trigger to start the NGS. 10. The NGS will prompt you to verify correct application. Trigger the NGS if correct. 11. Select DIAGNOSTIC DATA LINK and press trigger to start the NGS. 12. Follow the NGS prompt PRESS TRIGGER TO CONTINUE or PRESS CANCEL TO BYPASS. 13. Select ABS ANTI-LOCK BRAKE MODULE and press trigger to start the NGS. 14. Select FUNCTION TESTS and press trigger to start the NGS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7715 15. Select SERVICE BLEED FUNCTION and press trigger to start the NGS. 16. Select PRESS TRIGGER TO BEGIN. NOTE: The brake pedal should be depressed while this procedure is functioning. Perform at least five service bleed procedures. 17. Repeat conventional bleed procedure as outlined in steps 1 through 4. 18. If brake pedal feels spongy, repeat NGS service bleed procedure as outlined in steps 5 through 16 and repeat conventional bleed steps 1 through 4. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Front Brake Caliper: Specifications Anchor Plate Bolts 125-169 ft.lb Caliper Bleeder Screws 11-14 ft.lb Caliper Bolts 21-26 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Front > Page 7720 Brake Caliper: Specifications Bore Diameter 2.01 in Adaptor Bolts 70 ft.lb Caliper Bleeder Screws 12-18 ft.lb Caliper Bolts 20 ft.lb Caliper Flow Bolts 23-29 ft.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Page 7721 Brake Caliper: Diagrams (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service Precautions > Customer Safety Information Brake Caliper: Customer Safety Information WARNING: Always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or front disc brake rotor that contacts the wheel. Installing wheels without proper metal to metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and could allow the wheel to come off while the vehicle is in motion, causing loss of control. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service Precautions > Customer Safety Information > Page 7724 Brake Caliper: Technician Safety Information WARNING: ^ Asbestos fiber dust may be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies should be cleaned using a vacuum cleaner recommended for use with asbestos fibers such as brake/clutch/service vacuum. The bag must be labeled per osha instructions, sealed, and the trash hauler notified as to the bag's contents. If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government-approved toxic dust purifying respirators. Grinding or sanding brake linings, pads, rotors, drums or clutch facings should be performed using properly exhaust-ventilated equipment. Occupational Health And Safety Act (OSHA) requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians performing brake or clutch repair should be present in the area. ^ The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. ^ Brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. Wash hands thoroughly after handling. if brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. ^ Always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or front disc brake rotor that contacts the wheel. Installing wheels without proper metal to metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and could allow the wheel to come off while the vehicle is in motion, causing loss of control. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service Precautions > Customer Safety Information > Page 7725 Brake Caliper: Vehicle Damage Warnings WARNING: ^ Always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or front disc brake rotor that contacts the wheel. Installing wheels without proper metal to metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and could allow the wheel to come off while the vehicle is in motion, causing loss of control. ^ The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. CAUTION: ^ Do not use heat to loosen a seized lug nut. Heat can damage the wheel and the wheel bearings. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service Precautions > Page 7726 Brake Caliper: Description and Operation The front disc brake caliper: ^ Is a pin slider, dual piston type. ^ Has two caliper pistons. ^ The caliper housing has a fluid inlet at the center of the bore. A square section seal fitted into an annular groove in the caliper cylinder bore seals against hydraulic pressure, while rubber boots seal the caliper pistons and caliper bore from contamination. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Anchor Plate Brake Caliper: Service and Repair Anchor Plate REMOVAL 1. Remove the brake pads. 2. Remove the front disc brake caliper anchor plate. a. Remove the two front disc brake caliper anchor plate bolts. b. Remove the front disc brake caliper anchor plates. Install Front Disc Brake Caliper Anchor Plate INSTALLATION 1. Install the front disc brake caliper anchor plate. a. Position the front disc brake caliper anchor plate. b. Install the front disc brake caliper anchor plate bolts. 2. Install the brake pads. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 7729 Brake Caliper: Service and Repair Bleeding WARNING: ^ Brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. Wash hands thoroughly after handling. if brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: ^ Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. ^ Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: ^ When any part of the hydraulic system has been disconnected for repair or replacement, air may get in to the system and cause spongy brake pedal action. This requires the bleeding of the affected portions of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment Brake Bleeder. 1. Connect a clear waste line to the affected disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Open the bleeder screw and cycle the brake pedal 25 to 30 times or until no more air is seen at the waste line. Tighten Disc Brake Caliper Bleeder Screw 3. Tighten the disc brake caliper bleeder screw to proper specification. 4. Disconnect the waste line. 5. Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid, C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A, DOT 3. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 7730 Brake Caliper: Service and Repair Front Overhaul DISASSEMBLY 1. Remove the front disc brake caliper. 2. Drain the remaining brake fluid from the front disc brake caliper. 3. Secure the disc brake caliper in a vise. 4. Remove the caliper pistons. a. Place a block of wood between the caliper bridge and the caliper pistons. b. Apply low air pressure to the fluid port in the disc brake caliper. c. Force out the caliper pistons to the block of wood. d. Remove the block of wood and the caliper pistons. 5. Remove and discard the piston seals and boots. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 7731 (Part 2 Of 2) 6. If the front disc brake caliper is leaking, replace the piston seals. If the cylinder bores are excessively scored or corroded, replace the front disc brake caliper. NOTE: Do not hone the cylinder bores. Pistons are not available for honed cylinder bores. CAUTION: ^ Never reuse piston seals and dust boots. ^ Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended period of time. ASSEMBLY 1. Lubricate the piston boot, caliper piston, piston seal, and cylinder bores with High Performance Brake Fluid C6AZ- 19542-AB or DOT3 equivalent meeting Ford specification ESA-M6C25-A. Install Caliper Pistons 2. Install the caliper pistons. a. Install the piston seal. b. Install the piston boot on the caliper piston. c. Insert the caliper piston. CAUTION: Be careful not to damage or dislodge the piston seal. d. Press the caliper piston into the cylinder bore being careful not to cock the caliper piston. 3. Install the front disc brake caliper. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 7732 Removal and Installation WARNING: Asbestos fiber dust may be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies should be cleaned using a vacuum cleaner recommended for use with asbestos fibers such as brake/clutch/service vacuum. The bag must be labeled per osha instructions, sealed, and the trash hauler notified as to the bag's contents. If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government-approved toxic dust purifying respirators. Grinding or sanding brake linings, pads, rotors, drums or clutch facings should be performed using properly exhaust-ventilated equipment. Occupational Health And Safety Act (OSHA) requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians performing brake or clutch repair should be present in the area. REMOVAL 1. Loosen the lug nuts. a. Remove the center cap. b. With the weight of the vehicle on the wheels, CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and the wheel bearings. 2. Raise and support the vehicle. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. 3. Remove the wheel and tire assembly. a. Remove the lug nuts. b. Remove the wheel and tire assembly. 4. Inspect the brake shoes and linings for wear or contamination. NOTE: Replace the lining if worn to or past specifications. Replace the brake shoes and linings in complete axle sets. 5. Disconnect the front brake hose. a. Remove the front brake hose bolt. b. Remove the copper washers. Plug the front brake hose. c. Disconnect the front brake hose. WARNING: Brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. Wash hands thoroughly after handling. if brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. 6. Remove the disc brake caliper. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 7733 a. Remove the two caliper bolts. b. Lift the front disc brake caliper off the front disc brake caliper anchor plate. 7. Measure the front disc brake rotor thickness. ^ Replace the front disc brake rotor if not within specifications. 8. Inspect the disc brake caliper for leaks. ^ If leaks are found, disassembly is required. INSTALLATION 1. Install the front disc brake caliper and bolts; torque to 28-36 Nm (21-26 ft. lbs.). 2. 2. Install the front brake hose; torque banjo bolt to 30-40 Nm (23-29 ft. lbs.). ^ Use new copper washers to connect the front brake hose. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 7734 3. Bleed the front disc brake caliper. See: Bleeding 4. Clean the wheel hub mounting surface. WARNING: Always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or front disc brake rotor that contacts the wheel. Installing wheels without proper metal to metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and could allow the wheel to come off while the vehicle is in motion, causing loss of control. Install Tire And Wheel Assembly 5. Install the tire and wheel assembly. 6. Inspect the brake operation. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 7735 Brake Caliper: Service and Repair Rear Adapter REMOVAL 1. Disconnect the parking brake cable and conduit. 2. Remove the parking brake shoe and lining. 3. Remove the axle shaft. Refer to Transmission and Drivtrain. Remove Rear Wheel Disc Brake Adapter 4. Remove the rear wheel disc brake adapter. a. Remove the bolts. b. Remove the rear wheel disc brake adapter. Install Rear Wheel Disc Brake Adapter INSTALLATION 1. To install, reverse the removal procedure. Overhaul DISASSEMBLY 1. Remove the rear disc brake caliper. CAUTION: Do not remove the caliper guide pins or caliper guide pin boots unless a problem is suspected. The caliper guide pins are meant to be sealed for life and are not repairable. At the time of publication there are no approved materials or procedures to lubricate the caliper slide pins. Other greases may swell the guide pin boots resulting in contamination and accelerated corrosion or wear of the caliper guide pin mechanism. 2. Drain the remaining brake fluid from the rear disc brake caliper. 3. Secure the rear disc brake caliper in a vise. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 7736 Remove Caliper Piston 4. Remove the caliper piston. a. Place a block of wood between the caliper bridge and the caliper piston. b. Apply low air pressure to the fluid port in the rear disc brake caliper. c. Force out the caliper piston to the block of wood. d. Remove the block of wood and the caliper piston. Remove Piston Seal And Dust Boot 5. Remove and discard the piston seal and dust boot. NOTE: Do not hone the cylinder bore. Pistons are not available for honed cylinder bores. If the rear disc brake caliper cylinder bore is excessively scored or corroded, replace the rear disc brake caliper. CAUTION: ^ Never reuse the piston seal or dust boot. ^ Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended period of time. ASSEMBLY 1. Lubricate the following with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A, DOT 3. a. Cylinder bore. b. Piston seal. c. Caliper piston. d. Piston dust boot. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 7737 2. Install the piston seal. 3. Use Driver Handle and Piston Dust Seal Replacer to install the piston dust boot. 4. Install the caliper piston. CAUTION: Be careful not to damage or dislodge the piston seal. 5. Install the rear disc brake caliper. Removal and Installation WARNING: Asbestos fiber dust may be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies should be cleaned using a vacuum cleaner recommended for use with asbestos fibers such as brake/clutch/service vacuum. The bag must be labeled per osha instructions, sealed, and the trash hauler notified as to the bag's contents. If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government-approved toxic dust purifying respirators. Grinding or sanding brake linings, pads, rotors, drums or clutch facings should be performed using properly exhaust-ventilated equipment. Occupational Health And Safety Act (OSHA) requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians performing brake or clutch repair should be present in the area. REMOVAL 1. Loosen the lug nuts. a. Remove the center cap. b. With the weight of the vehicle on the wheels, loosen the lug nuts. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and the wheel bearings. 2. Raise and support the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 7738 WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. 3. Remove the wheel and tire assembly. a. Remove the lug nuts. b. Remove the wheel and tire assembly. Inspect Lining 4. Inspect the brake shoes and linings for wear or contamination. a. Replace the lining if worn to or past specification. NOTE: Replace the brake shoes and linings in complete axle sets. 5. Disconnect the brake hose. a. Remove the brake hose bolt. b. Remove the copper washers and plug the brake hose. c. Disconnect the brake hose. WARNING: Brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. Wash hands thoroughly after handling. if brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Remove Rear Disc Brake Caliper 6. Remove the rear disc brake caliper. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 7739 a. Remove the bolts. b. Lift the rear disc brake caliper off the rear disc brake caliper anchor plate. CAUTION: Do not remove the caliper guide pins or caliper guide pin boots unless a problem is suspected. The caliper guide pins are meant to be sealed for life and are not repairable. At the time of publication there are no approved materials or procedures to lubricate the caliper guide pins. Other greases may swell the caliper guide pin boots resulting in contamination and accelerated corrosion or wear of the caliper guide pin mechanism. 7. Inspect the rear disc brake caliper for leaks. ^ If leaks are found, disassembly is required. Measure Rear Disc Brake Rotor Thickness 8. Measure the rear disc brake rotor thickness. ^ Replace the rear disc brake rotor if not within specification. Install Rear Disc Brake Caliper INSTALLATION 1. Install the front disc brake caliper and bolts; torque to 27 Nm (20 ft. lbs.). CAUTION: To prevent interference with rear disc brake caliper operation, install only the correct caliper bolt. NOTE: ^ Make sure the stainless steel shoe slippers are correctly positioned. Replace if worn or damaged. ^ Make sure the notches on the upper ends of the brake shoe and linings are seated over the upper shoe slipper. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Anchor Plate > Page 7740 2. Install the front brake hose; torque banjo bolt to 30-40 Nm (23-29 ft. lbs.). ^ Use new copper washers to connect the brake hose. 3. Bleed the disc brake caliper. See: Bleeding 4. Clean the wheel hub mounting surface. WARNING: Always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or disc brake rotor that contacts the wheel. Installing wheels without proper metal to metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and come off while the vehicle is in motion, causing loss of control. Install Wheel And Tire Assembly 5. Install the wheel and tire assembly. a. Position the wheel and tire assembly. b. Install the lug nuts and snug to fully seat wheel and tire assembly, lower the vehicle. c. Tighten the lug nuts. d. Install the center cap. 6. Inspect the brake system for normal operation. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Hydraulic brake fluid color must conform with the requirements of Federal Motor Vehicle Safety Standard 116. Under this standard, brake fluids are visually different from other automotive fluids such as transmission, power steering and engine oil. High Performance DOT3 Brake Fluid Ford Specification ESA-M6C25-A Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Page 7747 Brake Fluid Level Sensor/Switch: Description and Operation FLOAT AND MAGNET The brake fluid level warning switch is an integral part of the brake master cylinder reservoir. It consists of a float containing a magnet and a reed switch mounted in the bottom of the brake master cylinder reservoir. PURPOSE When the brake fluid in the brake master cylinder reservoir gets to a predetermined level, the floating magnet actuates the reed switch, causing the red brake warning indicator to illuminate. Loss of brake fluid from either the primary (front) or secondary (rear) system will cause this system to activate. If the brake fluid level warning switch is inoperative, the brake master cylinder reservoir must be replaced. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Brake Hose Brake Hose/Line: Specifications Brake Hose TIGHTENING SPECIFICATIONS Front Brake Hose Brackets ............................................................................................................................................................ 13-17 Nm (10-12 ft. lbs.) Brake Hose Plug .......................................................................................... ........................................................................ 13-17 Nm (10-12 ft. lbs.) Rear Hose Bracket Bolt ................................................................................................................................ .................................. 12-15 Nm (9-11 ft. lbs.) Caliper Hose Bolt ........................................................ ................................................................................................................... 40 Nm (29 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Brake Hose > Page 7752 Brake Hose/Line: Specifications Brake Line TIGHTENING SPECIFICATIONS Brake Line Front .................................................................................................................................................... ................................. 15-20 Nm (11-14 ft. lbs.) Rear ........................................................................... ........................................................................................................... 15-20 Nm (11-14 ft. lbs.) Master Cylinder Line Front .................................................................................................................................................... ................................. 22-28 Nm (17-20 ft. lbs.) Rear ........................................................................... ........................................................................................................... 15-20 Nm (11-14 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Page 7753 Brake Hose/Line: Description and Operation CAUTION: Only Ford authorized inlet hydraulic brake lines should be used. These tubes are of a specific design and should be replaced with Ford or equivalent parts only. LINE MATERIAL Steel tubing is used in the hydraulic lines between the brake master cylinder and the front line connector, between the rear line connector and the rear disc brake caliper and between the brake master cylinder and the flexible brake hose at the rear axle. NOTE: Double flared brake line should provide good leak proof connections. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Front Brake Hose/Line: Service and Repair Front WARNING: ^ brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. ^ The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle, this can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. REMOVAL 1. Raise and support the vehicle. Disconnect Front Brake Hose 2. Disconnect the front brake hose. a. Remove the front brake hose bolt. b. Remove and discard the copper washers. Plug the front brake hose. c. Disconnect the front brake hose. Remove Front Brake Hose 3. Remove the front brake hose. a. Disconnect the front brake line fitting and plug the line. b. Remove the plug. c. Remove the brake hose frame bolt. d. Separate the anti-lock brake wire from the front brake hose and remove the front brake hose. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Front > Page 7756 Install Front Brake Hose INSTALLATION To install, reverse the removal procedure. Bleed the front brakes. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Front > Page 7757 Brake Hose/Line: Service and Repair Rear WARNING: ^ brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. ^ The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle, this can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. REMOVAL 1. Raise and support the vehicle. Disconnect Rear Brake Hose 2. Disconnect the rear brake hose. a. Remove the rear brake hose bolt. b. Remove and discard the copper washers. Plug the rear brake hose. c. Disconnect the rear brake hose. Remove Right Rear Brake Hose 3. On the right side, remove the rear brake hose. a. Disconnect the rear brake tube fitting and plug the tube. b. Remove the rear brake hose clip. c. Remove the rear brake hose. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Front > Page 7758 Remove Left Rear Brake Hose 4. On the left side, remove the rear brake hose. a. Disconnect the two rear brake tube fittings. b. Plug the brake tube coming from the front of vehicle. c. Remove the bracket bolt. d. Remove the rear brake hose and bracket assembly. Install Rear Brake Hose INSTALLATION To install, reverse the removal procedure. Bleed the rear brakes. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications Brake Proportioning/Combination Valve: Specifications TIGHTENING SPECIFICATIONS Fluid Control Valve .............................................................................................................................. ..................................... 30-49 Nm (22-36 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 7762 Brake Proportioning/Combination Valve: Description and Operation Brake Master Cylinder Fluid Control Valve PURPOSE The brake master cylinder fluid control valve regulates the hydraulic pressure in the rear brake system. It is located on the brake master cylinder and is screwed into the rearmost outlet port. When the brake pedal is applied, the full brake pressure passes through the brake master cylinder fluid control valve to the rear brake system until the valve's split point is reached. Above its split point, the brake master cylinder fluid control valve begins to reduce the hydraulic pressure to the rear brakes, creating a balanced braking condition between the front and rear wheels to minimize rear wheel lockup during In Case Of The Front Brake System Malfunction - the brake master cylinder fluid control valve has a bypass feature which allows full hydraulic pressure to the rear brake system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 7763 Brake Proportioning/Combination Valve: Service and Repair WARNING: Brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Remove Brake Master Cylinder Fluid Control Valve REMOVAL 1. Disconnect and plug the brake tube. 2. Remove the brake master cylinder fluid control valve. Install Brake Master Cylinder Fluid Control Valve INSTALLATION To install, reverse removal procedure, noting the following: ^ Tighten the fluid control valve to 30-49 Nm (22-36 ft. lbs.). ^ Tighten the brake line to 15-20 Nm (11-14 ft. lbs.). ^ Bleed the rear brakes. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications TIGHTENING SPECIFICATIONS EHCU Bolts ......................................................................................................................................... ...................................... 30-40 Nm (23-29 ft. lbs.) EHCU Bracket Bolts ............................................. ..................................................................................................................... 17-23 Nm (13-16 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 7767 Hydraulic Control Assembly - Antilock Brakes: Description and Operation OPERATION When the brakes are applied, brake fluid is forced from the brake master cylinder outlet ports to the Hydraulic Control Unit (HCU) inlet ports. The fluid pressure is transmitted through three normally open solenoid valves inside the HCU, through the outlet ports of HCU to the rear brakes. One circuit of the brake master cylinder feeds the front brakes, while the other circuit feeds the rear brakes. If the Electro-Hydraulic Control Unit ( EHCU) senses that a wheel is about to lock, based on wheel speed sensor data, the solenoid valve will pulse closed preventing more fluid from entering that circuit. The HCU then reads the sensor signal from the affected wheel again. If the wheel is still decelerating, the normally closed solenoid valve for that circuit is opened. Any remaining pressure between the normally open valve and the brake is relieved into the HCU accumulator. Once the affected wheel returns to vehicle speed, the HCU returns the solenoid valves to their normal condition allowing fluid flow to the affected brake. Brake Pulsation During the 4WABS operation, the driver may feel a pulsation in the brake pedal, accompanied by a slight up and down movement in the pedal height. In addition, a mechanical noise from the engine compartment may be heard. The pedal effort and pedal feel during normal braking are similar to that of a conventional power brake system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 7768 Hydraulic Control Assembly - Antilock Brakes: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the anti-lock brake control module electrica1 connectors. 3. Disconnect the hydraulic brake tubes. a. Disconnect the two inlet hydraulic brake tubes. b. Disconnect the three outlet hydraulic brake tubes. WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. CAUTION: ^ Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. ^ Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: Plug each open port to prevent brake fluid from spilling. 4. Remove the Electro-Hydraulic Control Unit (EHCU). a. Remove the bolts. b. Remove the EHCU. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 7769 5. If necessary, remove the EHCU bracket. a. Remove the bolts. b. Remove the EHCU bracket. INSTALLATION 1. If removed, install the EHCU bracket. a. Position the bracket. b. Install the EHCU bracket bolts. 2. Install the EHCU. a. Position the EHCU. b. Install the bolts. 3. Connect the hydraulic brake tubes. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 7770 CAUTION: Only Ford authorized inlet hydraulic brake tubes should be used. These tubes are of specific design and should only be replaced with authorized service parts. 4. Connect the two anti-lock brake control module electrical connectors. 5. Connect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 6. Bleed the brake hydraulic system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications Brake Master Cylinder: Specifications TIGHTENING SPECIFICATIONS Master Cylinder Nuts ........................................................................................................................... ...................................... 22-28 Nm (17-20 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Diagrams > Brake Fluid Reservoir Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Diagrams > Brake Fluid Reservoir > Page 7776 Brake Master Cylinder Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Diagrams > Page 7777 Brake Master Cylinder: Description and Operation Brake Master Cylinder The brake master cylinder is a dual-piston type. The brake master cylinder is assisted by a power brake booster. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Brake Master Cylinder: Initial Inspection and Diagnostic Overview NORMAL CONDITIONS The following conditions are considered normal and are not indications that the brake master cylinder is in need of service. Condition 1: During normal operation of the master cylinder, the fluid level in the brake master cylinder reservoir will rise during brake application and fall during release. The net fluid level (i.e., after brake application and release) will remain unchanged. Condition 2: A trace of brake fluid will exist on the booster shell below the master cylinder mounting flange. This results from the normal lubricating action of the master cylinder bore and seal. Condition 3: Fluid level will decrease with pad wear. ABNORMAL CONDITIONS Changes in brake pedal feel or travel are indicators that something could be wrong in the brake system. Refer to the Symptom Chart for abnormal condition diagnosis. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7780 Brake Master Cylinder: Component Tests and General Diagnostics Bypass Conditions Test 1. Check the fluid in the brake master cylinder. Fill the brake master cylinder reservoir if low or empty. 2. Observe the fluid level in the brake master cylinder reservoir. If after several brake applications the fluid level remains the same, measure the wheel turning torque required to rotate the wheels with brakes applied as follows: ^ Apply the brakes slowly to a minimum of 445 N (100 lbs) of force and hold for approximately 15 seconds. With the brakes still applied, exert torque on the front wheels to 101 Nm (75 ft. lbs.). If the wheel can be rotated, the brake master cylinder is bypassing. ^ Repair or replace the brake master cylinder. See: Service and Repair/Master Cylinder, Brakes Compensator Port Test SUPPLYING ADDITIONAL FLUID The purpose of the compensator ports in the brake master cylinder is to supply any additional brake fluid required by the system due to brake pad wear and to allow brake fluid returning from the brake lines to the brake master cylinder to enter the brake master cylinder reservoir. FLUID RETURN The returning brake fluid will cause a slight turbulence in the brake master cylinder reservoir. Turbulence seen in the brake master cylinder reservoir upon release of the brake pedal is normal and shows that the compensating ports are not plugged. Non-Pressure Leaks BRAKE FLUID LOSS The only part of the brake system that could have a brake fluid loss that does not appear when the system is under pressure is the brake master cylinder reservoir area. Brake fluid loss could be caused by a missing or poorly-fitted brake master cylinder filler cap, a punctured or otherwise damaged brake master cylinder reservoir, a missing or damaged brake master cylinder filler cap gasket or by missing, damaged or poorly-fitted sealing grommets between the brake master cylinder and the brake master cylinder reservoir. CAUTION: The brake master cylinder reservoir grommets are not separately serviceable and must be replaced as a unit with a new brake master cylinder reservoir. See: Service and Repair/Master Cylinder, Brakes Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Page 7781 Brake Master Cylinder: Adjustments 1. Remove the brake master cylinder. 2. Adjust the power brake booster to brake master cylinder push rod length. a. Measure the power brake booster to brake master cylinder push rod. b. If necessary, adjust the screw to 24.89-25.27 mm (0.0980-0.995 inch). 3. Install master cylinder. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir Brake Master Cylinder: Service and Repair Brake Fluid Reservoir WARNING: Brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the brake master cylinder fluid level warning switch electrical connector. 3. Use a suitable suction device to drain the brake master cylinder reservoir. 4. Carefully pry up on the brake master cylinder reservoir to remove. INSTALLATION 1. Install the brake master cylinder reservoir. a. Lubricate the two grommets with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A, DOT 3 and insert the grommets in the brake master cylinder. b. Press the brake master cylinder reservoir into the grommets until it snaps. c. Connect the brake master cylinder fluid level warning switch electrical connector. d. Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19S42-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A, DOT3. NOTE: Whenever replacing the brake master cylinder reservoir, replace the grommets. 2. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 7784 NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 7785 Brake Master Cylinder: Service and Repair Master Cylinder, Brakes Bench WARNING: ^ brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: ^ Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. ^ Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: ^ When any part of the hydraulic system has been disconnected for repair or replacement, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment Brake Bleeder. 1. Support the brake master cylinder body in a vise and fill the brake master cylinder reservoir with specified brake fluid. ^ Use High Performance DOT 3 Brake Fluid C6AZ-19S42-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A, DOT 3. 2. Install plugs in the front and rear brake outlet ports. Bleed the front brake system first. Loosen Plug 3. Loosen the plug in the front outlet port and slowly depress the primary piston. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 7786 Tighten Plug 4. Tighten the plug in the front outlet port and release the primary piston. 5. Repeat this procedure until clear, bubble-free brake fluid flows. 6. Repeat steps 3, 4, and 5 for the rear outlet port with the front outlet port plugged. 7. Tighten the plugs and try to depress the primary piston. The piston will not depress if all the air is out of the system. 8. Install the brake master cylinder filler cap and install the brake master cylinder in the vehicle. 9. Bleed the system. In-Vehicle WARNING: ^ brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: ^ Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. ^ Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: ^ When any part of the hydraulic system has been disconnected for repair or replacement, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment Brake Bleeder. WHEN TO PERFORM THIS PROCEDURE This procedure only needs to be performed if the 4WABS hydraulic control unit (HCU) has been replaced. DESCRIPTION One conventional pressure bleed cycle consists of advancing the brake pedal to its depressed position, opening the rear disc brake caliper bleeder screw, allowing fluid to be released into the waste container, closing the rear disc brake caliper bleeder screw and releasing the brake pedal to its full upright position. PURPOSE Performing the NGS program routine drives entrapped air from the otherwise inaccessible lower section of the 4WABS valve into the upper sections (accessible by bleeding the brakes). Subsequent bleedings remove the air from the system. PROCEDURE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 7787 1. Disconnect the brake master cylinder outlet lines. Install Short Brake Tubes 2. Install short brake tubes with ends submerged in the brake master cylinder reservoir and fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A, DOT 3. 3. Have an assistant pump the brake pedal until clear, bubble-free brake fluid flows from both brake lines. 4. Remove the short brake lines and install the brake outlet lines. 5. Bleed each brake tube at the brake master cylinder as follows: a. Have an assistant pump the brake pedal 10 times and then hold firm pressure on the brake pedal. b. Loosen the rearmost brake tube fittings until a stream of brake fluid comes out. c. Have an assistant maintain pressure on the brake pedal while tightening the brake tube fitting. Repeat this operation until clear, bubble-free fluid comes out. d. Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the front brake tube. Tighten Brake Tubes 6. Tighten the brake lines. Overhaul WARNING: Brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. DISASSEMBLY 1. Remove brake master cylinder. 2. Clean the outside of the brake master cylinder. 3. Remove the brake master cylinder filler cap and drain the remaining brake fluid. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 7788 4. Remove the brake master cylinder fluid control valve. 5. On speed control equipped vehicles, remove the brake Pressure switch. Remove Primary Piston Assembly 6. Remove the primary piston assembly. a. Depress the (A) primary piston and remove the (B) snap ring. b. Remove and discard the primary piston assembly. 7. Remove the secondary piston assembly. a. Plug the rear outlet port and, if necessary, plug the brake pressure switch port. b. Apply compressed air into the front outlet pot and carefully remove the secondary piston assembly and discard. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 7789 8. Use isopropyl alcohol to clean and inspect the brake master cylinder bore for damage. NOTE: If the brake master cylinder bore is damaged, the brake master cylinder must be replaced. ASSEMBLY 1. Use clean High-Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A, DOT 3; lubricate the new piston assembly seals. 2. Carefully install the secondary piston assembly. 3. Carefully install the primary piston assembly. 4. Install the snap ring. a. Depress the primary piston. b. Install the snap ring. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 7790 5. Install the brake master cylinder fluid control valve. 6. On speed control equipped vehicles, install the brake pressure switch. Install Brake Master Cylinder Filler Cap 7. Fill the (A) brake master cylinder reservoir and install the (B) brake master cylinder filler cap. 8. Bleed the brake master cylinder. See: Bleeding/Bench 9. Install brake master cylinder. Removal and Installation WARNING: Brake fluid contains polyglycol ethers and polyglycols. avoid contact with eyes. Wash hands thoroughly after handling. if brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. REMOVAL 1. Disconnect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 7791 2. Disconnect the brake fluid level warning switch electrical connector. 3. On speed control equipped vehicles, disconnect the brake pressure switch electrical connector. 4. Disconnect the two brake lines and plug the lines and the brake master cylinder ports. 5. Remove the two brake master cylinder nuts and the master cylinder. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 7792 INSTALLATION To install, reverse the removal procedure, noting the following: ^ Tighten the mounting nuts to 22-28 Nm (17-20 ft. lbs.). ^ Tighten the line nuts to 15-20 Nm (11-14 ft. lbs.). ^ Bleed the brake master cylinder. See: Bleeding/Bench ^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi.) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Specifications Parking Brake Cable: Specifications TIGHTENING SPECIFICATIONS Cable and conduit Clip Bolt ........................................................................................................................................................ 15-20 Nm (11-14 ft. lbs.) Cable Retainer Clip Screw ........................................................................................................................................................... 11-15 Nm (8-11 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Parking Brake Cable: Service and Repair Front REMOVAL 1. Remove parking brake control. Disconnect Front Parking Brake Cable From RH Parking Brake Rear Cable And Conduit 2. Disconnect the (A) front parking brake cable from the (B) RH parking brake rear cable and conduit. 3. Remove the front parking brake cable and conduit. a. Pry the rubber seal from the front floor pan. b. Compress the retainer and release the front parking brake cable and conduit from the bracket. c. Remove the front parking brake cable and INSTALLATION To install, reverse the removal procedure, noting the following: ^ Tighten mounting bolts to 15-20 Nm (11-15 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front > Page 7799 Parking Brake Cable: Service and Repair Rear Left WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rh kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. REMOVAL 1. Relieve the tension on the parking brake system. a. Pull the front parking brake cable and conduit. b. Insert a suitable retainer. NOTE: Make sure the parking brake control is fully released. 2. Raise and support the vehicle. 3. Separate the RH parking brake rear cable and conduit from the LH parking brake rear cable and conduit at the parking brake cable equalizer. 4. Compress the parking brake cable clip. Remove the LH parking brake rear cable and conduit from the parking brake cable bracket. 5. Remove the screw. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front > Page 7800 Release Parking Brake Rear Cable And Conduit 6. Compress the retainer and release the (A) parking brake rear cable and conduit from the (B) rear disc brake caliper anchor plate. 7. Unclip the parking brake rear cable and conduit from the parking brake lever. INSTALLATION To install, reverse the removal procedure, noting the following: ^ Tighten the cable strap bolt to 11-15 Nm (8-11 ft. lbs.). Right Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front > Page 7801 WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rh kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. REMOVAL 1. Relieve the tension on the parking brake system. a. Pull the front parking brake cable and conduit. b. Insert a suitable retainer. NOTE: Make sure the parking brake control is fully released. 2. Raise and support the vehicle. Disconnect Front Parking Brake Cable From RH Parking Brake Rear Cable And Conduit 3. Disconnect the (A) front parking brake cable and conduit from the (B) RH, parking brake rear cable and conduit. 4. Compress the parking brake cable clip. Remove the RH parking brake rear cable and conduit from the parking brake cable equalizer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front > Page 7802 Remove Screw 5. Remove the screw. Release Parking Brake Rear Cable And Conduit 6. Compress the retainer and release the (A) parking brake rear cable and conduit from the (B) rear disc brake caliper anchor plate. 7. Unclip the parking brake rear cable and conduit from the parking brake lever. 8. Remove the pushpin located in the crossmember and the RH parking brake rear cable and conduit. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front > Page 7803 INSTALLATION To install, reverse the removal procedure, noting the following: ^ Tighten the cable strap bolt to 11-15 Nm (8-11 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications Parking Brake Control: Specifications TIGHTENING SPECIFICATIONS Control To Cowl Panel Bolts ..................................................................................................................................................... 15-20 Nm (11-15 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 7807 Parking Brake Control: Service and Repair REMOVAL 1. Relieve the tension on the parking brake system. Make sure the parking brake control is fully released. ^ Pull the front parking brake cable and conduit. ^ Insert a suitable retainer. 2. Remove the front door scuff plate. 3. Remove the cowl side trim panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 7808 4. Pull to release the three clips and remove the lower instrument panel steering column cover. 5. Remove the parking brake remote release lever screws. Unhook Remote Release Lever From Parking Brake Control 6. Unhook the remote release lever from the parking brake control. Remove the conduit from the clip. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 7809 7. Separate the parking brake control from the cowl panel. a. Remove the bolts. b. Disconnect the parking brake signal switch connector. c. Separate the parking brake control from the cowl panel. 8. Disconnect the front parking brake cable and conduit from the parking brake control. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 7810 9. Remove the parking brake control. a. Compress the connector; release the front parking brake cable and conduit. b. Remove the front parking brake cable and conduit. c. Remove the parking brake control. INSTALLATION To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair Parking Brake Shoe: Service and Repair REMOVAL 1. Relieve the tension on the parking brake system. a. Pull the front parking brake cable and conduit. b. Insert a suitable retainer. NOTE: Make sure the parking brake control is fully released. 2. Remove the rear disc brake rotor. 3. Remove the brake shoe retracting spring. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Page 7814 4. Remove the brake shoe adjusting screw spring. 5. Remove the brake adjuster screw 6. Remove the rear brake shoe hold-down springs. 7. Remove the rear brake shoes. 8. Inspect the components for excessive wear or damage and replace as required. INSTALLATION 1. Install the rear brake shoes. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Page 7815 2. Install the front brake shoe hold-down springs. 3. Install the brake adjuster screw. 4. Install the brake shoe adjusting screw spring. 5. Install the brake shoe retracting spring. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Page 7816 6. Use the Brake Adjusting Gauge to measure the inside diameter of the drum portion of the rear disc brake rotor. 7. Use the Brake Adjusting Gauge to set the rear brake shoe diameter. 8. Install the rear disc brake rotor. 9. Apply tension to the parking brake system. a. Hold the front parking brake cable and conduit taut. b. Remove the retainer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications DIMENSIONS Effective Diameter ............................................................................................................................... ........................................ 250.01 mm (9.843 inch) Outside Diameter ................................................. ...................................................................................................................... 270.12 mm (10.992 inch) Push Rod Length ....................................................................................................................................................... 24.89-25.27 mm (0.980-0.995 inch) TIGHTENING SPECIFICATIONS Mounting Nuts ..................................................................................................................................... ............................. 21.2-28.8 Nm (15.5-21 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 7821 Power Brake Booster Internal Components Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 7822 Vacuum Brake Booster: Description and Operation Power Brake System Components Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 7823 Power Brake Booster Internal Components The power brake booster: ^ Is a dual diaphragm, vacuum assisted power brake booster. ^ Reduces brake pedal pressure and travel distance. ^ Is located on the LH side of the bulkhead in the engine compartment, between the brake pedal and brake master cylinder. ^ Is divided into two separate chambers by the diaphragm. ^ Will not operate if vacuum is restricted, or if the vacuum related power brake components fail. ^ Is replaced as an assembly. ^ If the power assist fails, the brake system will continue to operate, with increased brake pedal effort. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Vacuum Brake Booster: Initial Inspection and Diagnostic Overview 1. Check the hydraulic brake system for leaks or insufficient fluid. 2. With the transmission in NEUTRAL, stop the engine and apply the parking brake control. Apply the brake pedal several times to exhaust all vacuum in the system. 3. Apply the brake pedal and hold it in the applied position. Start the engine. If the vacuum system is operating, the brake pedal will tend to move downward under constant foot pressure. If no motion is felt, the power brake booster system is not functioning. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7826 Vacuum Brake Booster: Component Tests and General Diagnostics Inspect all hoses and connections. All unused vacuum connectors should be capped. Hoses and their connections should be properly secured and in good condition with no holes or collapsed areas. 1. Remove the vacuum booster hose from the power brake booster and check the valve connection. Manifold vacuum should be available at the check valve end of the vacuum booster hose with the engine at idle speed and the transmission in NEUTRAL. If the manifold vacuum is available to the power brake booster, connect the vacuum booster hose to the power brake booster and repeat Steps 2 and 3 of the Brake Booster Operation Check. If no downward movement of the brake pedal is felt, replace the power brake booster. 2. Operate the engine a minimum of 10 seconds at fast idle. Stop the engine, and let the vehicle stand for 10 minutes. Then apply the brake pedal with approximately 89 N (20 lbs) of force. The brake pedal feel should be the same as that noted with the engine operating. If the brake pedal feels hard (no power assist), replace the check valve and retest. If the brake pedal feels spongy, bleed the hydraulic system to remove air. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Page 7827 Vacuum Brake Booster: Service and Repair REMOVAL 1. Remove the brake master cylinder. Disconnect Power Brake Booster Hose 2. Disconnect the power brake booster hose. a. Compress the clamp. b. Disconnect the power brake booster hose. Brake Pedal To Power Brake Booster Push Rod 3. Disconnect the brake pedal to power brake booster push rod. a. Remove the self-locking pin. b. Remove the (A) brake on/off (BOO) switch from the (B) brake master cylinder push rod. c. Remove the brake master cylinder push rod spacers. d. Remove the brake master cylinder push rod bushing. Remove Bulkhead Sound Insulator 4. Remove the bulkhead sound insulator. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Page 7828 Remove Power Booster 5. Remove the power brake booster. a. Remove the nuts. b. Remove the power brake booster. CAUTION: Make sure the power brake booster rubber reaction disc is properly installed. If the power brake booster rubber reaction disc is not seated properly, excessive brake pedal travel and extreme power brake sensitivity will occur. NOTE: If the power brake booster rubber reaction disc is dislodged, a silver colored valve plunger will be exposed. If the power brake booster rubber reaction disc cannot be located, installed and aligned, then the power brake booster must be replaced. INSTALLATION To install, reverse the removal procedure. Start the engine and check brake operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Description and Operation Vacuum Brake Booster Check Valve: Description and Operation Power Brake System Components The power brake booster check valve: ^ Is located on the front of the power brake booster. ^ Is positioned between the power brake booster and the power brake booster hose. ^ Closes when the engine is turned off. ^ Is part of the power brake booster, and is not replaced separately. ^ In the closed position, traps engine vacuum in the power brake booster. ^ Reserves vacuum and allows several power assisted brake applications with the engine off. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Description and Operation > Page 7832 Vacuum Brake Booster Check Valve: Testing and Inspection NOTE: The function of the power brake booster check valve is to allow manifold vacuum to enter the power brake booster and prevent the escape of vacuum in case manifold vacuum is lost during sustained full throttle operation. To test the function of the power brake booster check valve: ^ Start and run the engine for at least 10 seconds. ^ Operate the brake pedal to check for power assist. ^ Disconnect the vacuum booster hose from the power brake booster. Do not remove the check valve from the power brake booster. ^ There should be enough vacuum retained in the power brake booster for at least one more power-assisted brake operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations ABS Main Relay: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations > Page 7837 Power Distribution Relay Box The 4 Wheel Anti-Lock Brake System Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control Module: > 98-9-15 > May > 98 > ABS - Lamp ON/DTC B1342 Stored Electronic Brake Control Module: Customer Interest ABS - Lamp ON/DTC B1342 Stored Article No. 98-9-15 05/11/98 ^ BRAKES - 4WABS - ABS LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) B1342 STORED IN MEMORY AND/OR CODES NOT LISTED IN WORKSHOP MANUAL VEHICLES BUILT THROUGH 2/12/98 ^ LAMP - ABS LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) B1342 STORED IN MEMORY AND/OR CODES NOT LISTED IN WORKSHOP MANUAL - VEHICLES BUILT THROUGH 2/12/98 LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR ISSUE The Anti-lock Brake System (ABS) lamp may illuminate and Diagnostic Trouble Code (DTC) B1342 may be stored in memory and/or New Generation Star (NGS) Tester may read "Invalid Code." This may be caused by the Nonvolatile Random Access Memory (NVRAM) chip inside the anti-lock brake control module not resetting at low residual voltages. ABS brake function may become inoperative, however, normal braking operation will be maintained. ACTION Replace the anti-lock brake control module. Modules with a build date of 2/19/98 or later have been revised to incorporate a new NVRAM chip. Refer to the appropriate Workshop Manual, Section 206-09, for replacement procedures. PART NUMBER PART NAME F75Z-2C065-AA Anti-lock Brake Control Module (F-150) F75Z-20065-BA Anti-lock Brake Control Module (F-250 LD) F7SZ-2C065-CA Anti-lock Brake Control Module (Expedition, Navigator) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 980915A Diagnose And Replace 0.6 Hr. ABS Module - F-Series, Expedition, And Navigator DEALER CODING CONDITION BASIC PART NO. CODE 2C065 42 OASIS CODES: 206000, 301000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > 98-9-15 > May > 98 > ABS - Lamp ON/DTC B1342 Stored Electronic Brake Control Module: All Technical Service Bulletins ABS - Lamp ON/DTC B1342 Stored Article No. 98-9-15 05/11/98 ^ BRAKES - 4WABS - ABS LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) B1342 STORED IN MEMORY AND/OR CODES NOT LISTED IN WORKSHOP MANUAL VEHICLES BUILT THROUGH 2/12/98 ^ LAMP - ABS LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) B1342 STORED IN MEMORY AND/OR CODES NOT LISTED IN WORKSHOP MANUAL - VEHICLES BUILT THROUGH 2/12/98 LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR ISSUE The Anti-lock Brake System (ABS) lamp may illuminate and Diagnostic Trouble Code (DTC) B1342 may be stored in memory and/or New Generation Star (NGS) Tester may read "Invalid Code." This may be caused by the Nonvolatile Random Access Memory (NVRAM) chip inside the anti-lock brake control module not resetting at low residual voltages. ABS brake function may become inoperative, however, normal braking operation will be maintained. ACTION Replace the anti-lock brake control module. Modules with a build date of 2/19/98 or later have been revised to incorporate a new NVRAM chip. Refer to the appropriate Workshop Manual, Section 206-09, for replacement procedures. PART NUMBER PART NAME F75Z-2C065-AA Anti-lock Brake Control Module (F-150) F75Z-20065-BA Anti-lock Brake Control Module (F-250 LD) F7SZ-2C065-CA Anti-lock Brake Control Module (Expedition, Navigator) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 980915A Diagnose And Replace 0.6 Hr. ABS Module - F-Series, Expedition, And Navigator DEALER CODING CONDITION BASIC PART NO. CODE 2C065 42 OASIS CODES: 206000, 301000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 7851 Electronic Brake Control Module: Specifications TIGHTENING SPECIFICATIONS Control Module Screws .............................................................................................................................................................. 4-5 Nm (36-44 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 7852 Electronic Brake Control Module: Locations Engine View The 4 Wheel Anti-Lock Brake System Module is located in the left side of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 7853 Electronic Brake Control Module: Diagrams 4 Wheel Anti-Lock Brake System Module (C146) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 7854 4 Wheel Anti-Lock Brake System Module (C147) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 7855 Electronic Brake Control Module: Description and Operation COMPONENTS The Electronic Hydraulic Control Unit (EHCU) consists of the anti-lock brake control module and the hydraulic control unit (HCU). NOTE: The anti-lock brake control module can be replaced if it is inoperative. If the HCU is inoperative, the EHCU must be replaced as an assembly. PURPOSE The EHCU monitors the electromechanical components of the system. Malfunction of the anti-lock brake system will cause the EHCU to shut off or inhibit the system. However, normal power-assisted braking remains. Malfunctions are indicated by the yellow ABS warning indicator in the instrument cluster. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 7856 Electronic Brake Control Module: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the two anti-lock brake control module electrical connectors. 3. Disconnect the pump motor electrica1 connector from the ABS module. 4. Remove the anti-lock brake control module. ^ Remove the screws. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 7857 CAUTION: Ensure that the replacement anti-lock brake control module identification sticker reads EXP. Use of any other module could result in diminished ABS performance. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Page 7862 Brake Fluid Level Sensor/Switch: Description and Operation FLOAT AND MAGNET The brake fluid level warning switch is an integral part of the brake master cylinder reservoir. It consists of a float containing a magnet and a reed switch mounted in the bottom of the brake master cylinder reservoir. PURPOSE When the brake fluid in the brake master cylinder reservoir gets to a predetermined level, the floating magnet actuates the reed switch, causing the red brake warning indicator to illuminate. Loss of brake fluid from either the primary (front) or secondary (rear) system will cause this system to activate. If the brake fluid level warning switch is inoperative, the brake master cylinder reservoir must be replaced. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Service and Repair Braking Sensor/Switch: Service and Repair REMOVAL Disconnect the brake pedal to power brake booster push rod. 1. Remove the self-locking pin. 2. Remove the brake on/off (BOO) switch. 3. Separate the (A) BOO switch from the (B) brake master cylinder push rod. 4. Remove the brake master cylinder push rod spacer. 5. Remove the brake master cylinder push rod bushing. INSTALLATION To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Anti-Lock Brake Sensor Screws 63-80 in.lb Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Differential Speed Sensor Wheel Speed Sensor: Locations Differential Speed Sensor Body View The Differential Speed Sensor is located on rear axle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Differential Speed Sensor > Page 7871 Wheel Speed Sensor: Locations Wheel Speed Sensor Left Front Engine View The Left Front Wheel 4 Wheel Anti-Lock Brake System Sensor is located at the left front wheel. Right Front Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Differential Speed Sensor > Page 7872 Engine View The Right Front Wheel 4 Wheel Anti-Lock Brake System Sensor is located at the Right front wheel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring Wheel Speed Sensor: Service and Repair Toothed Ring Rear The differential case must be disassembled and assembled to replace the rear sensor indicator. Refer to Transmission and Drivetrain for details. Removal and Installation The front brake anti-lock sensor indicator is integral to the front wheel hub. Refer to Transmission and Drivetrain for details. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 7875 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Front REMOVAL 1. Disconnect the front brake anti-lock sensor electrical connector. 2. Remove the front disc brake rotor shield. 3. Remove the (A) two front brake anti-lock sensor bolts and the (B) front brake anti-lock sensor. INSTALLATION 1. To install, reverse the removal procedure. Rear REMOVAL Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 7876 Remove the rear brake anti-lock sensor. 1. Disconnect the electrical connector. 2. Remove the bolt. 3. Remove the rear brake anti-lock sensor. NOTE: Remove all dirt from mounting surface and sensor to prevent contamination of rear axle lubrication. INSTALLATION Clean and inspect the rear brake anti-lock sensor. 1. Clean the axle mounting surface. Use care not to get dirt in the rear axle housing. 2. Inspect and clean the magnetized rear brake anti-lock sensor pole piece. 3. Inspect the rear anti-lock brake control o-ring for damage. Replace if necessary. 4. Lightly lubricate the rear anti-lock brake control o-ring with engine oil. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 7877 Rear Brake And Anti-Lock Sensor Install the rear brake anti-lock sensor. 1. Position the rear brake anti-lock sensor and install the rear brake anti-lock sensor bolt. NOTE: Do not apply force to the plastic rear brake anti-lock sensor connector. 2. Connect the electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 7885 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 7886 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 7887 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 7888 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 7889 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Ignition Switch Lock Cylinder: Service and Repair Functional REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key and turn to the RUN position. (2) Press the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. INSTALLATION 1. To install, reverse the removal procedure. - Verify ignition switch lock cylinder operation. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 7892 Ignition Switch Lock Cylinder: Service and Repair Non-Functional REMOVAL 1. Disconnect the battery ground cable. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. 4. Remove the ignition switch lock cylinder. - Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. - Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the bearing and the gear. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 7893 - Thoroughly clean all drill shavings from the steering column and inspect for damage. INSTALLATION 1. To install, reverse the removal procedure, using a new ignition switch lock cylinder. - Verify ignition switch lock cylinder operation. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Neutral Safety Switch: Locations Transmission View The Digital Transmission Range Sensor is located at left side of the automatic transmission. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 7897 Digital Transmission Range Sensor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Engine View The Starter Motor Relay is located at right rear of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 7902 Starter Relay: Description and Operation The starter motor solenoid relay switch: - Controls current to the starter solenoid. - Is engaged by the ignition switch. - Connects the battery to the starter motor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair Battery Cable: Service and Repair REMOVAL 1. Disconnect the battery ground cables. 1. Disconnect the negative battery cable. 2. Disconnect the positive battery cable. 2. Remove the two starter motor solenoid relay switch cable nuts. 3. Remove the (A) negative battery cable body ground nut and the (B) negative battery cable body ground. 4. Remove the body ground bolt. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Page 7907 5. Remove the starter motor solenoid terminal cover. 6. Disconnect the starter motor connections. 1. Remove the (A) starter motor ground cable nut and disconnect the (B) starter motor ground cable. 2. Remove the (C) solenoid cable nut and disconnect the (D) solenoid cable. 3. Remove the (E) starter motor positive cable nut and disconnect the (F) starter motor positive cable. 7. Remove the cables. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Page 7908 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Alternator Brush > Component Information > Specifications Alternator Brush: Specifications Brush and Terminal Holder Screws ....................................................................................................................................................... 3-4 Nm 27-35 Lb In Generator Brush Screws ..................................................................................................................... ............................................ 2.8-4.0 Nm 2.5-3.5 Lb In Generator Brush and Terminal Holder Screws ................................................................................................................................ 2.8-3.4 Nm 21-30 Lb In Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Alternator Brush > Component Information > Specifications > Page 7914 Alternator Brush: Service and Repair REMOVAL 1. Remove the generator. 2. Remove the (A) generator brush and terminal holder and the (B) voltage regulator assembly. 1. Remove the voltage regulator screws. 2. Remove the (A) generator brush and terminal holder and (B) voltage regulator assembly. 3. Separate the (A) generator brush and terminal holder from the (B) voltage regulator. 1. Remove the screw cap. 2. Remove the generator brush and terminal holder screws. 3. Separate the (A) generator brush and terminal holder from the (B) voltage regulator. INSTALLATION 1. Install the (A) brush and terminal holder on the (B) voltage regulator. 1. Position (A) brush and terminal holder on the (B) voltage regulator. 2. Install the generator brush and terminal holder screws. 3. Install the screw cap. CAUTION: Make sure screw cap is installed over the proper screw to prevent accidental shorting of the battery positive connection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Alternator Brush > Component Information > Specifications > Page 7915 2. Install the (A) generator brush and terminal holder and (B) voltage regulator assembly. 1. Depress the (C) brushes and insert a (D) wire to hold brushes during installation. 2. Install the (A) generator brush and terminal holder and (B) voltage regulator assembly. 3. Install the voltage regulator screws. - Remove the (D) wire. 3. Install the generator. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Specifications Voltage Regulator: Specifications Voltage Regulator Screws ................................................................................................................... ............................................. 2.3-3.4 Nm 21-30 Lb In Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Specifications > Page 7919 Voltage Regulator: Description and Operation The charging system consists of the: - Generator (GEN) (A). - Integral Voltage Regulator (VR) (B). The standard heavy duty generator provides 130 amps of direct current to charge the vehicle battery. It has an integral voltage regulator (B). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Specifications > Page 7920 Voltage Regulator: Service and Repair REMOVAL 1. Remove the generator. 2. Remove the (A) generator brush and terminal holder and the (B) voltage regulator assembly. 1. Remove the voltage regulator screws. 2. Remove the (A) generator brush and terminal holder and (B) voltage regulator assembly. INSTALLATION 1. Install the (A) generator brush and terminal holder and (B) voltage regulator assembly. 1. Depress the (C) brushes and insert a (D) wire to hold brushes during installation. 2. Install the (A) generator brush and terminal holder and (B) voltage regulator assembly. 3. Install the voltage regulator screws. - Remove the (D) wire. 2. Install the generator. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder Ignition Lock: All Technical Service Bulletins Ignition Key - Hard To Remove From Ignition Cylinder Article No. 99-16-4 08/09/99 ^ IGNITION KEY - HARD TO REMOVE FROM IGNITION CYLINDER ^ IGNITION KEY - HARD TO TURN FORD: 1992-1999 ECONOLINE 1997-1999 EXPEDITION, F-150, F-25C 1999 SUPER DUTY F SERIES LINCOLN: 1998-1999 NAVIGATOR This TSB article is being republished in its entirety to add vehicles covered by this TSB. ISSUE A hard to turn ignition key, and/or a hard to remove key from ignition cylinder may occur on some vehicles. This may be caused by a misaligned shift column shaft bushing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 7930 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 7931 ACTION A diagnostic and repair procedure has been developed to correctly repair the concern. Refer to the following Figures 1 through 3 for details. PART NUMBER PART NAME F3TZ-7L278-A Shift Column Shaft Bushing OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-5-9 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991604A Replace Ignition Lock 0.4 Hr. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 7932 Cylinder 991604B Replace Bushings 1.1 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 7335 42 OASIS CODES: 112000, 602300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Customer Interest: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder Ignition Lock: Customer Interest Ignition Key - Hard To Remove From Ignition Cylinder Article No. 99-16-4 08/09/99 ^ IGNITION KEY - HARD TO REMOVE FROM IGNITION CYLINDER ^ IGNITION KEY - HARD TO TURN FORD: 1992-1999 ECONOLINE 1997-1999 EXPEDITION, F-150, F-25C 1999 SUPER DUTY F SERIES LINCOLN: 1998-1999 NAVIGATOR This TSB article is being republished in its entirety to add vehicles covered by this TSB. ISSUE A hard to turn ignition key, and/or a hard to remove key from ignition cylinder may occur on some vehicles. This may be caused by a misaligned shift column shaft bushing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Customer Interest: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 7938 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Customer Interest: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 7939 ACTION A diagnostic and repair procedure has been developed to correctly repair the concern. Refer to the following Figures 1 through 3 for details. PART NUMBER PART NAME F3TZ-7L278-A Shift Column Shaft Bushing OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-5-9 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991604A Replace Ignition Lock 0.4 Hr. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Customer Interest: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 7940 Cylinder 991604B Replace Bushings 1.1 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 7335 42 OASIS CODES: 112000, 602300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Lock: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions Four Wheel Drive Selector Switch: All Technical Service Bulletins Transfer Case - Multiple Electrical Malfunctions Article No. 01-16-6 08/20/01 ^ LAMP - 4X4 "LOW RANGE" LIGHT DIMLY LIT ^ SWITCHES - TRANSFER CASE MODE SWITCH - 4X4 HI/LOW SWITCH SHORTED OUT ^ WINDSHIELD WIPERS - INTERMITTENT WIPERS ERRATIC OR INOPERABLE ^ TRANSFER CASE - WATER PRESENT IN TRANSFER CASE FORD: 1997 EXPEDITION, F-150, F-250 LD This article is being republished in its entirety to update the labor time. ISSUE Water may be present in the transfer case on some vehicles. This may cause: ^ Transfer Case Mode Switch to become inoperative ^ The 4X4 "Low Range" light to appear dimly lit ^ The intermittent wipers to become erratic or inoperative ^ Vehicle Speed Sensor (VSS) Diagnostic Trouble Codes (DTCs) P0500, P0503, P1500, and P1501 to be set. This may be caused by water splashing into the transfer case through the vent tube assembly, possibly causing the transfer case mode switch to short out, and/or the VSS gear to swell and set the VSS DTCs listed above. Shorting out the transfer case mode switch may cause the intermittent wiper mode to function erratically, as well as possibly causing the 4X4 light to work incorrectly. ACTION Inspect, diagnose, and/or replace the necessary components. Refer to the following Service Procedure for details. SERVICE PROCEDURE Procedure for VSS Gear: 1. Inspect VSS gear in the transfer case for looseness. 2. Replace Gear (C80Z-17285-B) as necessary. Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Mode Switch: 1. Check resistance of the Transfer Case Mode Switch. 2. The resistance of the switch should be at least 100,000 ohms. If it is less, replace the switch (3-Position Switch, E7TZ-7E440-A, manual shift only). Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Vent Replacement: 1. Remove old vent hose from fitting on front of transfer case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Lock: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 7946 2. Attach end of new Vent Hose (F75Z-7A246-M) to fitting, and route the hose up over the top of the transfer case (Figure 1). 3. Attach the clip on the vent hose to the top of the vertical rib on the transfer case extension housing to support the end of the hose (Figure 2). NOTE FOR ALL WATER CONCERNS, DRAIN AND REFILL THE TRANSFER CASE WITH FRESH FLUID (XT-2-QDX), AND REPLACE THE VENT HOSE WITH THE REVISED PART. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Lock: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 7947 SUPERSEDES:97-11-19 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011606A Drain And Refill Transfer 1.2 Hrs. Case, Inspect And/Or Replace VSS Gear And Transfer Case Mode Switch, And Install Vent Kit DEALER CODING CONDITION BASIC PART NO. CODE 7D494 49 OASIS CODES: 202000, 206000, 508000, 508300, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Lock: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 7953 2. Attach end of new Vent Hose (F75Z-7A246-M) to fitting, and route the hose up over the top of the transfer case (Figure 1). 3. Attach the clip on the vent hose to the top of the vertical rib on the transfer case extension housing to support the end of the hose (Figure 2). NOTE FOR ALL WATER CONCERNS, DRAIN AND REFILL THE TRANSFER CASE WITH FRESH FLUID (XT-2-QDX), AND REPLACE THE VENT HOSE WITH THE REVISED PART. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Lock: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 7954 SUPERSEDES:97-11-19 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011606A Drain And Refill Transfer 1.2 Hrs. Case, Inspect And/Or Replace VSS Gear And Transfer Case Mode Switch, And Install Vent Kit DEALER CODING CONDITION BASIC PART NO. CODE 7D494 49 OASIS CODES: 202000, 206000, 508000, 508300, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 7960 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 7961 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 7962 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 7963 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 7964 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Ignition Switch Lock Cylinder: Service and Repair Functional REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key and turn to the RUN position. (2) Press the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. INSTALLATION 1. To install, reverse the removal procedure. - Verify ignition switch lock cylinder operation. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 7967 Ignition Switch Lock Cylinder: Service and Repair Non-Functional REMOVAL 1. Disconnect the battery ground cable. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. 4. Remove the ignition switch lock cylinder. - Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. - Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the bearing and the gear. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional > Page 7968 - Thoroughly clean all drill shavings from the steering column and inspect for damage. INSTALLATION 1. To install, reverse the removal procedure, using a new ignition switch lock cylinder. - Verify ignition switch lock cylinder operation. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations Neutral Safety Switch: Locations Transmission View The Digital Transmission Range Sensor is located at left side of the automatic transmission. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 7972 Digital Transmission Range Sensor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > Customer Interest: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition Starter Cable: Customer Interest Starting System- No Crank Condition TSB 06-19-14 10/02/06 NO CRANK / STARTER TERMINAL FATIGUE FORD: 1997-2007 Crown Victoria 1997-2004 F-150 Heritage 1997-2006 Expedition 1998-2006 E-Series 1999-2006 F-Super Duty 2002-2007 Explorer 2004-2006 F-150 2007 Explorer Sport Trac LINCOLN: 1998-2006 Navigator 2003-2005 Aviator MERCURY: 1997-2007 Grand Marquis 2002-2007 Mountaineer ISSUE Some vehicles may exhibit a no crank condition due to an open circuit in the starter relay to starter motor circuit at the starter motor connection. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE A new starter terminal wiring pigtail kit is released eliminating the need to replace the entire harness for the terminal connection. NOTE TERMINAL KIT ONLY SERVICES THE STARTER RELAY TO STARTER MOTOR CIRCUIT. THE KIT DOES NOT SERVICE STARTER MOTOR BATTERY POWER CIRCUIT. Refer to instruction sheet contained in Wiring Pigtail Kit for wiring harness service procedure. NOTE REFERENCE THE APPROPRIATE WORKSHOP MANUAL SERVICE SECTION 303-06 FOR REMOVAL AND INSTALLATION OF THE STARTER MOTOR WIRING TERMINAL CONNECTION PROCEDURES. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061914A Install Wiring Pigtail kit (Do 0.4 Hr. Not Use With 14200A) MT061914 Claim Additional Labor Actual Required As Actual Time Time Or Use SLTS Operation If Available DEALER CODING Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > Customer Interest: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition > Page 7981 CONDITION BASIC PART NO. CODE 14A280 01 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition Starter Cable: All Technical Service Bulletins Starting System- No Crank Condition TSB 06-19-14 10/02/06 NO CRANK / STARTER TERMINAL FATIGUE FORD: 1997-2007 Crown Victoria 1997-2004 F-150 Heritage 1997-2006 Expedition 1998-2006 E-Series 1999-2006 F-Super Duty 2002-2007 Explorer 2004-2006 F-150 2007 Explorer Sport Trac LINCOLN: 1998-2006 Navigator 2003-2005 Aviator MERCURY: 1997-2007 Grand Marquis 2002-2007 Mountaineer ISSUE Some vehicles may exhibit a no crank condition due to an open circuit in the starter relay to starter motor circuit at the starter motor connection. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE A new starter terminal wiring pigtail kit is released eliminating the need to replace the entire harness for the terminal connection. NOTE TERMINAL KIT ONLY SERVICES THE STARTER RELAY TO STARTER MOTOR CIRCUIT. THE KIT DOES NOT SERVICE STARTER MOTOR BATTERY POWER CIRCUIT. Refer to instruction sheet contained in Wiring Pigtail Kit for wiring harness service procedure. NOTE REFERENCE THE APPROPRIATE WORKSHOP MANUAL SERVICE SECTION 303-06 FOR REMOVAL AND INSTALLATION OF THE STARTER MOTOR WIRING TERMINAL CONNECTION PROCEDURES. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061914A Install Wiring Pigtail kit (Do 0.4 Hr. Not Use With 14200A) MT061914 Claim Additional Labor Actual Required As Actual Time Time Or Use SLTS Operation If Available DEALER CODING Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition > Page 7987 CONDITION BASIC PART NO. CODE 14A280 01 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Starter Cable: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Starter Cable: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 7993 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Starter Cable: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 7994 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Starter Cable: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement Air Flow Meter/Sensor: All Technical Service Bulletins Mass Air Flow Sensor - Assembly Replacement Article No. 96-22-5 10/21/96 MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP FORD: 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR, EXPLORER, RANGER 1993-97 VILLAGER 1994-96 BRONCO 1994-97 ECONOLINE 1995-97 F-150, WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: The Mass Air Flow (MAF) sensor is not designed to be removed from its body (die-cast or plastic) for servicing. The sensing elements located inside the by-pass tube can be damaged by poking/probing/touching. ACTION: Service the MAF sensor as an assembly (refer to Figure 1). WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Starter Cable: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement > Page 7999 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Starter Cable: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 8005 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Starter Cable: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 8006 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Starter Cable: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement > Page 8011 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Armature > Component Information > Specifications Starter Armature: Specifications Starter Motor Armature Shaft Maximum Runout .................................................................................................................................... 0.09 mm (0.003 in) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Armature > Component Information > Specifications > Page 8016 Starter Armature: Testing and Inspection OPEN CIRCUIT TEST An open circuit starter motor armature may sometimes be detected by examining the commutator for evidence of burning. GROUNDED CIRCUIT TEST 1. This test will determine if any armature winding insulation has been damaged. Measure for resistance using 73 Digital Multimeter as shown between the commutator and the core. Infinite resistance indicates a normal condition; otherwise, replace the starter motor armature. 2. Check for continuity between the commutator and the shaft. Replace the starter motor armature if continuity is found. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Specifications > Torque Specification Starter Brush: Specifications Torque Specification Brush Plate Bolts ................................................................................................................................. ................................................... 2-3 Nm 17-26 Lb In Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Specifications > Torque Specification > Page 8021 Starter Brush: Specifications General Specification Starter Motor Brush Manufactured Length ............................................................................................................................................... 16.8 mm (0.66 in) Starter Motor Brush Spring Tension ...................................................................................... ............................................................................ 18 N (64 oz) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Drive/Bendix > Component Information > Description and Operation Starter Drive/Bendix: Description and Operation The starter drive: - Is operated by the starter solenoid. - Engages the flywheel to turn the engine. - Has an internal over-running clutch to disengage the starter motor when the engine starts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Drive/Bendix > Component Information > Testing and Inspection > Starter Drive Test Starter Drive/Bendix: Testing and Inspection Starter Drive Test 1. Remove the starter motor. 2. Secure the starter motor in a vise. 3. Connect the battery ground cable of a fully charged battery to the case of the starter motor. 4. Touch the positive lead from the battery to the S-terminal and verify that the starter drive ejects. CAUTION: Do not leave the positive lead of the battery connected to the starter motor S-terminal for more than 10 seconds. 5. Remove the positive lead from the starter motor. The ejected starter drive should return to its original position. 6. If the starter drive does not eject and return to position, repair or replace the starter motor. 7. Check the starter drive. It should turn freely in one direction, and positively engage to the armature when turned in the opposite direction. If not as specified, repair or replace the starter motor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Drive/Bendix > Component Information > Testing and Inspection > Starter Drive Test > Page 8027 Starter Drive/Bendix: Testing and Inspection Starter Drive/Flywheel Ring Gear Inspection 1. Remove the starter motor. 2. Check the wear patterns on the (A) starter drive and the (B) flywheel ring gear. If the wear pattern is normal, install the starter motor. 3. If the (A) starter drive gear and the flywheel ring gear are not fully meshing or the gears are (B) milled or damaged, replace the starter motor. Replace the flywheel ring gear. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Starter Relay: Locations Engine View The Starter Motor Relay is located at right rear of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 8031 Starter Relay: Description and Operation The starter motor solenoid relay switch: - Controls current to the starter solenoid. - Is engaged by the ignition switch. - Connects the battery to the starter motor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications Starter Solenoid: Specifications Solenoid Bolts ...................................................................................................................................... ................................................. 5-10 Nm 44-88 Lb In Starter Motor Solenoid Relay Switch Bolts ............................................................................................................................................ 7-9 Nm 61-79 Lb In Starter Motor Solenoid Relay Switch Terminal Nuts ............................................................................................................................ 5-11 Nm 44-97 Lb In Starter Solenoid B-Terminal Nut ............................................................................................................................................................ 7-9 Nm 61-79 Lb In Starter Solenoid M-Terminal Nut ....................................................................................................................................................... 9-14 Nm 79-123 Lb In Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications > Page 8035 Starter Solenoid: Description and Operation The starter solenoid: Is an electromagnet. - Engages the starter drive to the flywheel. - When energized, the contacts close, connecting the battery to the starter motor. This causes the starter motor to turn the starter drive. - Is kept in the energized condition by a hold-in winding until the starter switch is released. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications > Page 8036 Starter Solenoid: Testing and Inspection STARTER SOLENOID 1. Check the starter solenoid for continuity between the S- and M-terminals using the 73 Digital Multimeter. Replace the starter solenoid if there is no continuity. 2. Check for continuity between the S-terminal and the starter solenoid body. Replace the starter solenoid starter solenoid if there is no continuity. SOLENOID M-TERMINAL 1. Make sure that the starter solenoid is isolated from the starter motor. Use 73 Digital Multimeter to check for continuity between the S- and M-terminals. Also check for continuity between the S-terminal and starter motor body. If either check shows no continuity, the starter solenoid should be replaced. 2. Check for continuity between the M-terminal and the B-terminal. If there is no continuity, the starter solenoid should be replaced. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications > Page 8037 Starter Solenoid: Service and Repair WARNING: WHEN PERFORMING MAINTENANCE ON THE STARTING SYSTEM BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE PROTECTIVE CAPS ARE IN PLACE WHEN MAINTENANCE IS COMPLETE. REMOVAL 1. Disconnect the battery ground cable. 2. Remove the relay cover. 3. Disconnect the starter motor solenoid relay switch wires and cables. 1. Remove the insulator. 2. Disconnect the ignition switch signal wire. 3. Remove the starter motor solenoid relay switch terminal nuts. 4. Remove the engine control sensor wire and the generator wire. 5. Remove the battery cables. 4. Remove the starter motor solenoid relay switch. 1. Remove the starter motor solenoid relay switch bolts. 2. Remove the starter motor solenoid relay switch. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications > Page 8038 1. To install, reverse the removal procedure. NOTE: when the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Electrical Diode - Identification and Replacement Diode: Technical Service Bulletins Electrical Diode - Identification and Replacement Article No. 96-24-6 11/18/96 WIRING - ELECTRICAL DIODE IDENTIFICATION AND SERVICE REPLACEMENTS FORD: 1984-86 LTD 1984-88 EXP 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1984-86 MARQUIS 1984-87 LYNX 1984-92 MARK VII 1984-94 TOPAZ 1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1983-97 RANGER 1984-90 BRONCO II 1984-97 ECONOLINE, F-150-350 SERIES 1986-97 AEROSTAR 1991-97 EXPLORER 1995-97 WINDSTAR MEDIUM/HEAVY TRUCK: 1984-91 C SERIES, CL-CLT-9000 SERIES 1984-97 F & B SERIES, L SERIES 1986-97 CARGO SERIES 1996-97 AEROMAX, LOUISVILLE This TSB article is being republished in its entirety to update the applicable model years. ISSUE: Electrical system concerns that are due to diode failure may be serviced with an approved Ford service diode. Some electrical diodes used in early production vehicles are color coded for the purpose of size identification while others are stamped with a manufacture number. All Ford service diodes and current production diodes are identified by manufacture number. ACTION: If service is required, refer to the appropriate model/year Electrical and Vacuum Troubleshooting Manual (EVTM) to determine the size and location of the diode(s). Refer to the following Electrical Diode Application Chart for the correct service part number. NOTE: IF THE DIODE REQUIRING REPLACEMENT DOES NOT HAVE THE SAME RATING AS LISTED IN THE APPLICATION CHART, USE THE NEXT HIGHER RATED DIODE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Electrical Diode - Identification and Replacement > Page 8044 ELECTRICAL DIODE APPLICATION CHART PART NUMBER PART NAME E8DZ-10C912-A Diode - 1.0 Amp - 400V E8DZ-10C912-B Diode - 6.0 Amp - 400V OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 89-2-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 2770 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 8053 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 8054 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 8055 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 8056 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 8057 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 8058 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 8059 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 8060 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 8066 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 8067 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 8068 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 8069 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 8070 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 8071 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 8072 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 8073 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8078 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8079 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8080 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8081 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8082 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8083 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8084 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8085 Fuse: Electrical Diagrams Circuit-to-Fuse Cross Reference Compact Disc Changer ....................................................................................................................... ......................................................................... Fuse 3 Powertrain Control Module ............................ ............................................................................................................................................................. Fuse 1 Premium Sound Amplifier ........................................................................................................ ................................................................................... Fuse 5 Radio ................................................... .............................................................................................................................................................. .......... Fuse 3 Rear Integrated Control Panel ...................................................................................... ................................................................................................ Fuse 3 Sub-Woofer Power ................. .............................................................................................................................................................. ....................... Fuse 5 Trailer Tow Left Turn Relay ............................................................................. .......................................................................................................... Fuse 2 Trailer Tow Right Turn Relay ................................................................................................................................................... .................................. Fuse 2 Fuse 1 Fuse 1 - protects the following circuits: ^ Powertrain Control Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8086 Power Distribution Fuse 2 Fuse 2 - protects the following circuits: ^ Trailer Tow Left Turn Relay ^ Trailer Tow Right Turn Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8087 Power Distribution Fuse 3 Fuse 3 - protects the following circuits: ^ Radio ^ Rear Integrated Control Panel ^ Compact Disc Changer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8088 Power Distribution Fuse 5 Fuse 5 - protects the following circuits: ^ Sub-Woofer Power ^ Premium Sound Amplifier Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8089 Power Distribution Circuit-to-Fuse Cross Reference 4 Wheel Air Suspension Module ......................................................................................................... ........................................................................ Fuse 6 4 Wheel Air Suspension ................................. ........................................................................................................................................................... Fuse 20 4 Wheel Anti-Lock Brake System Module ............................................................................. ................................................................................... Fuse 25 4 Wheel Anti-Lock Brake System Relay ................................................................................................................................................... ................ Fuse 25 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8090 4X4 Center Axle Disconnect Solenoid ................................................................................................. ..................................................................... Fuse 23 Air Bag Diagnostic Monitor .............................. ............................................................................................................................................... Fuse 19 & 22 Autolamp Module ........................................................................................................................ ....................................................................... Fuse 4 & 29 Auxiliary A/C Control Module .................. .............................................................................................................................................................. . Fuse 23 Auxiliary A/C Mode Actuator ................................................................................................ ................................................................................... Fuse 23 Auxiliary A/C Relay ............................ .............................................................................................................................................................. .......... Fuse 7 Battery Saver Relay ...................................................................................................... ............................................................................................. Fuse 14 Blend Door Actuator ................ .............................................................................................................................................................. ..................... Fuse 5 Brake On/Off Switch .......................................................................................... ....................................................................................................... Fuse 13 Brake Pressure Switch .. .............................................................................................................................................................. ............................... Fuse 13 Cigar Lighter .......................................................................................... ...................................................................................................................... Fuse 3 Coil On Plugs .... .............................................................................................................................................................. ........................................... Fuse 30 Compass Sensor ....................................................................... .................................................................................................................................... Fuse 6 Console Blower Motor ......................................................................................................................... ....................................................................... Fuse 7 Data Link Connector ........................................ .......................................................................................................................................................... Fuse 12 Daytime Running Lamps Module .......................................................................................... ........................................................................ Fuse 5,16 & 26 Digital Transmission Range Sensor .. .............................................................................................................................................................. .... Fuse 5 & 21 Electronic Variable Orifice Module ............................................................................. ............................................................................................... Fuse 5 Flasher Relay .......................... .............................................................................................................................................................. ....................... Fuse 1 Fog Lamp Relay .............................................................................................. ........................................................................................................... Fuse 27 Function Selector Switch .................................................................................................................................................. ................................ Fuse 23 & 24 Generic Electronic Module ........................................................... ............................................................................................................ Fuse 6,18,15 & 20 Headlamp Relay ................................................................................................................................................... ........................................................ Fuse 4 Heated Backlight Switch ................................................. ........................................................................................................................................... Fuse 17 Heated Grid Relay ............................................................................................................................... ........................................................................ Fuse 6 Heater-A/C Control Assembly ........................ ............................................................................................................................................................. Fuse 5 High Beam Headlamps ............................................................................................................ .................................................................................. Fuse 16 Ignition Coil ......................................... .............................................................................................................................................................. ........ Fuse 30 Instrument Cluster ........................................................................................................ .................................................................................. Fuse 2,19 & 29 Instrument Cluster (Without Daytime Running Lamps) ............................................................................................................................................ Fuse 16 Instrument Illumination ........................................................................................................................ ...................................................................... Fuse 18 Interior Lamp Relay ........................................ ........................................................................................................................................................... Fuse 14 Junction Box Fuse/Relay Panel ............................................................................................. .................................................................................... Fuse 21 Junction Box Fuse Relay Panel Fuse 20 ......................................................................................................................................................... ........... Fuse 21 Left Headlamp ........................................................................................................... ................................................................................................ Fuse 28 Left Power/Heated Signal Mirror ................................................................................................................................................... ........................... Fuse 17 Main Light Switch ...................................................................................... ................................................................................................... Fuse 8,18 & 27 Overhead Trip Computer Module ................................................................................................................................ ......................................... Fuse 2 & 6 PCM Power Diode ................................................................... .................................................................................................................................. Fuse 30 Park Lamp Relay ......................................................................................................................................... ................................................................ Fuse 4 Passive Anti-Theft System Module ......................... .................................................................................................................................................. Fuse 15 Power Mirror Switch ....................................................................................................................... ............................................................................ Fuse 4 Radio Noise Capacitor ................................ .............................................................................................................................................................. . Fuse 30 Radio ................................................................................................................................... ........................................................................................ Fuse 8 Rear Integrated Control Panel ........ .............................................................................................................................................................. .............. Fuse 23 Rear Wiper Pump Relay ......................................................................................... ................................................................................................... Fuse 11 Recirculation Vacuum Solenoid ............................................................................................................................................... ................................. Fuse 23 Remote Anti-Theft Personality Module ................................................ ................................................................................................................ Fuse 4 & 8 Right Headlamp .............................................................................................................................................................. ........................................... Fuse 26 Right Power/Heated Signal Mirror ............................................. ............................................................................................................................... Fuse 17 Shift Lock Actuator ............................................................................................................................................... ...................................................... Fuse 6 Speed Control Servo/Amplifier Assembly ......................... .......................................................................................................................................... Fuse 5 Steering Wheel Rotation Sensor ......................................................................................................... ......................................................................... Fuse 6 Trailer Tow Battery Charge Relay ................. ............................................................................................................................................................ Fuse 23 Transmission Control Switch ................................................................................................. .................................................................................... Fuse 29 Washer Pump Relay ......................... .............................................................................................................................................................. ............ Fuse 11 Windshield Wiper Motor ........................................................................................... ................................................................................................ Fuse 11 Wiper High/Low Relay .......... .............................................................................................................................................................. ...................... Fuse 11 Wiper Run/Park Relay .................................................................................... ........................................................................................................... Fuse 11 Fuse 1 Fuse 1 - protects the following circuits: ^ Flasher Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8091 Power Distribution Fuse 2 Fuse 2 - protects the following circuits: ^ Instrument Cluster ^ Overhead Trip Computer Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8092 Power Distribution Fuse 3 Fuse 3 - protects the following circuits: ^ Cigar Lighter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8093 Power Distribution Fuse 4 Fuse 4 - protects the following circuits: ^ Park Lamp Relay ^ Headlamp Relay ^ Autolamp Module ^ Remote Anti-Theft Personality Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8094 ^ Power Mirror Switch Power Distribution Fuse 5 Fuse 5 - protects the following circuits: ^ Digital Transmission Range Sensor ^ Daytime Running Lamps Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8095 ^ Speed Control Servo/Amplifier Assembly ^ Heater-A/C Control Assembly ^ Blend Door Actuator ^ Electronic Variable Orifice Module Power Distribution Fuse 6 Fuse 6 - protects the following circuits: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8096 ^ Shift Lock Actuator ^ Generic Electronic Module ^ 4 Wheel Air Suspension Module ^ Compass Sensor ^ Steering Wheel Rotation Sensor ^ Heated Grid Relay ^ Overhead Trip Computer Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8097 Power Distribution Power Distribution Fuse 7 Fuse 7 - protects the following circuits: ^ Auxiliary A/C Relay ^ Console Blower Motor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8098 Power Distribution Fuse 8 Fuse 8 - protects the following circuits: ^ Radio ^ Main Light Switch ^ Remote Anti-Theft Personality Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8099 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8100 Power Distribution Fuse 11 Fuse 11 - protects the following circuits: ^ Washer Pump Relay ^ Wiper Run/Park Relay ^ Wiper High/Low Relay ^ Windshield Wiper Motor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8101 ^ Rear Wiper Pump Relay Power Distribution Fuse 12 Fuse 12 - protects the following circuits: ^ Data Link Connector Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8102 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: ^ Brake On/Off Switch ^ Brake Pressure Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8103 Power Distribution Fuse 14 Fuse 14 - protects the following circuits: ^ Battery Saver Relay ^ Interior Lamp Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8104 Power Distribution Fuse 15 Fuse 15 - protects the following circuits: ^ Generic Electronic Module ^ Passive Anti-Theft System Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8105 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: ^ Instrument Cluster (Without Daytime Running Lamps) ^ Daytime Running Lamps Module ^ High Beam Headlamps Power Source Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8106 Power is Supplied Through Multi-Function Switch Power Distribution Fuse 17 Fuse 17 - protects the following circuits: ^ Heated Backlight Switch ^ Left Power/Heated Signal Mirror Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8107 ^ Right Power/Heated Signal Mirror Power Distribution Fuse 18 Fuse 18 - protects the following circuits: ^ Main Light Switch ^ Generic Electronic Module ^ Instrument Illumination Power Source Power is Supplied Through Main Light Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8108 Power Distribution Fuse 19 Fuse 19 - protects the following circuits: ^ Instrument Cluster ^ Air Bag Diagnostic Monitor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8109 Power Distribution Fuse 20 Fuse 20 - protects the following circuits: ^ 4 Wheel Air Suspension ^ Generic Electronic Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8110 Power Distribution Fuse 21 Fuse 21 - protects the following circuits: ^ Digital Transmission Range Sensor ^ Junction Box Fuse/Relay Panel Fuse 20 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8111 Power Distribution Fuse 22 Fuse 22 - protects the following circuits: ^ Air Bag Diagnostic Monitor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8112 Power Distribution Fuse 23 Fuse 23 - protects the following circuits: ^ Trailer Tow Battery Charge Relay ^ 4X4 Center Axle Disconnect Solenoid Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8113 ^ Function Selector Switch ^ Rear Integrated Control Panel ^ Recirculation Vacuum Solenoid ^ Auxiliary A/C Mode Actuator ^ Auxiliary A/C Control Module Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8114 Fuse 24 Fuse 24 - protects the following circuits: ^ Function Selector Switch Power Distribution Fuse 25 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8115 Fuse 25 - protects the following circuits: ^ 4 Wheel Anti-Lock Brake System Module ^ 4 Wheel Anti-Lock Brake System Relay Power Distribution Fuse 26 Fuse 26 - protects the following circuits: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8116 ^ Daytime Running Lamps Module ^ Right Headlamp Power Source Power is Supplied Through Multi-Function Switch Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8117 Fuse 27 Fuse 27 - protects the following circuits: ^ Main Light Switch ^ Fog Lamp Relay Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8118 Fuse 28 Fuse 28 - protects the following circuits: ^ Left Headlamp Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8119 Fuse 29 Fuse 29 - protects the following circuits: ^ Autolamp Module ^ Instrument Cluster ^ Transmission Control Switch Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8120 Fuse 30 Fuse 30 - protects the following circuits: ^ Radio Noise Capacitor ^ Ignition Coil ^ PCM Power Diode ^ Coil On Plugs Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8121 Power Distribution Circuit-to-Fuse Cross Reference 4 Wheel Anti-Lock Brake System Module ........................................................................................... ..................................................................... Fuse 14 Accessory Delay Relay .................................... .......................................................................................................................................................... Fuse 25 Air Bag Diagnostic Monitor .................................................................................................... .................................................................................... Fuse 2 Air Suspension Service Switch ........... .............................................................................................................................................................. ........... Fuse 4 Air Suspension Solid State Compressor Relay .......................................................................................................................................................... Fuse 15 All Lock Relays ...................................................................................................................... ..................................................................................... Fuse 3 All Unlock Relays ............................... .............................................................................................................................................................. ........... Fuse 3 Auxiliary A/C Relay ...................................................................................................... ............................................................................................ Fuse 13 Compact Disc Changer ............ .............................................................................................................................................................. ...................... Fuse 6 Console Auxiliary Power Socket ....................................................................... ........................................................................................................ Fuse 11 Daytime Running Lamps Module ..................................................................................................................................... ........................................... Fuse 9 Drover's Unlock Relay ................................................................. ................................................................................................................................ Fuse 3 Engine Fuse Module (Fuse 1) ......................................................................................................................... ........................................................... Fuse 24 Engine Fuse Module (Fuse 2) ................................... ................................................................................................................................................. Fuse 16 Engine Fuse Module (Fuse 3) ........................................................................................................ .............................................................................. Fuse 6 Engine Fuse Module (Fuse 5) .................. .............................................................................................................................................................. ...... Fuse 6 Flip Window Relay ............................................................................................................ ........................................................................................ Fuse 29 Fog Lamp Relay ........................... .............................................................................................................................................................. .................. Fuse 9 Fuel Pump Relay .................................................................................................. ...................................................................................................... Fuse 19 Headlamp Relay ............. .............................................................................................................................................................. ................................ Fuse 8 Heated Grid Relay .................................................................................. ................................................................................................................... Fuse 27 Horn Relay ......... .............................................................................................................................................................. ............................................ Fuse 5 Hybrid Cooling Fan Relay ........................................................... .............................................................................................................................. Fuse 29 Ignition Switch .................................................................................................................................................. ................................................ Fuse 20 & 21 Instrument Panel (I/P) Auxiliary Power Socket ......................................................................................................................................................... Fuse 10 I/P Blower Relay .................................................................................................................... .................................................................................... Fuse 23 Junction Box Fuse/Relay Panel Battery Feed ............................................................................................................................................................ Fuse 22 Junction Box Fuse/Relay Panel ............................................................................................. ........................................................................... Fuse 25 & 27 Main Light Switch .............................. .............................................................................................................................................................. .... Fuse 7 & 8 Multi-Function Switch ................................................................................................... .............................................................................................. Fuse 8 Park Lamp Relay ...................... .............................................................................................................................................................. ..................... Fuse 7 PCM Power Relay ............................................................................................. ........................................................................................................ Fuse 24 Power Seat Control Switch .................................................................................................................................................. ...................................... Fuse 18 Premium Sound Amplifier ............................................................... ............................................................................................................................ Fuse 6 Radio .......... .............................................................................................................................................................. ................................................... Fuse 6 Rear Integrated Control Panel ............................................. ......................................................................................................................................... Fuse 6 Rear Wiper Down Motor Relay ..................................................................................................................... ............................................................ Fuse 12 Rear Wiper Up Motor Relay ..................................... ................................................................................................................................................. Fuse 12 Shift On The Fly Relay ................................................................................................................... ........................................................................... Fuse 17 Sub-Woofer Power .................................... .............................................................................................................................................................. .... Fuse 6 Trailer Electronic Brake Controller ...................................................................................... ..................................................................................... Fuse 28 Trailer Tow Backup Lamp Relay ..... .............................................................................................................................................................. ............. Fuse 1 Trailer Tow Battery Charge Relay ............................................................................. ................................................................................................ Fuse 16 Trailer Tow Running Lamp Relay ................................................................................................................................................... ............................ Fuse 1 Transfer Case Shift Relay .......................................................................... ................................................................................................................ Fuse 17 Fuse 1 Fuse 1 - protects the following circuits: ^ Trailer Tow Running Lamp Relay ^ Trailer Tow Backup Lamp Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8122 Power Distribution Fuse 2 Fuse 2 - protects the following circuits: ^ Air Bag Diagnostic Monitor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8123 Power Distribution Fuse 3 Fuse 3 - protects the following circuits: ^ All Unlock Relay ^ All Lock Relay ^ Driver's Unlock Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8124 Power Distribution Fuse 4 Fuse 4 - protects the following circuits: ^ Air Suspension Service Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8125 Power Distribution Fuse 5 Fuse 5 - protects the following circuits: ^ Horn Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8126 Power Distribution Fuse 6 Fuse 6 - protects the following circuits: ^ Radio ^ Premium Sound Amplifier ^ Compact Disc Changer ^ Rear Integrated Control Panel Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8127 ^ Engine Fuse Module Fuse 3 ^ Engine Fuse Module Fuse 5 ^ Sub-Woofer Power Power Distribution Fuse 7 Fuse 7 - protects the following circuits: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8128 ^ Main Light Switch ^ Park Lamp Relay Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8129 Power Distribution Fuse 8 Fuse 8 - protects the following circuits: ^ Main Light Switch ^ Headlamp Relay ^ Multi-function Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8130 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8131 Power Distribution Fuse 9 Fuse 9 - protects the following circuits: ^ Daytime Running Lamps Module ^ Fog Lamp Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8132 Power Distribution Fuse 10 Fuse 10 - protects the following circuits: ^ Instrument Panel Auxiliary Power Socket Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8133 Power Distribution Fuse 11 Fuse 11 - protects the following circuits: ^ Console Auxiliary Power Socket Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8134 Power Distribution Fuse 12 Fuse 12 - protects the following circuits: ^ Rear Wiper Up Motor Relay ^ Rear Wiper Down Motor Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8135 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: ^ Auxiliary A/C Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8136 Power Distribution Fuse 14 Fuse 14 - protects the following circuits: ^ 4 Wheel Anti-Lock Brake System Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8137 Power Distribution Fuse 15 Fuse 15 - protects the following circuits: ^ Air Suspension Solid State Compressor Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8138 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: ^ Trailer Tow Battery Charge Relay ^ Engine Fuse Module Fuse 2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8139 Power Distribution Fuse 17 Fuse 17 - protects the following circuits: ^ Shift On The Fly Relay ^ Transfer Case Shift Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8140 Power Distribution Fuse 18 Fuse 18 - protects the following circuits: ^ Power Seat Control Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8141 Power Distribution Fuse 19 Fuse 19 - protects the following circuits: ^ Fuel Pump Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8142 Power Distribution Fuse 20 Fuse 20 - protects the following circuits: ^ Ignition Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8143 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8144 Power Distribution Fuse 21 Fuse 21 - protects the following circuits: ^ Ignition Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8145 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8146 Power Distribution Fuse 22 Fuse 22 - protects the following circuits: ^ Junction Box Fuse/Relay Panel Battery Feed Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8147 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8148 Power Distribution Fuse 23 Fuse 23 - protects the following circuits: ^ Instrument Panel Blower Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8149 Power Distribution Fuse 24 Fuse 24 - protects the following circuits: ^ PCM Power Relay ^ Engine Fuse Module Fuse 1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8150 Power Distribution Fuse 25 Fuse 25 - protects the following circuits: ^ Junction Box Fuse/Relay Panel ^ Accessory Delay Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8151 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8152 Power Distribution Fuse 27 Fuse 27 - protects the following circuits: ^ Junction Box Fuse/Relay Panel ^ Heated Grid Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8153 Power Distribution Fuse 28 Fuse 28 - protects the following circuits: ^ Trailer Electronic Brake Controller Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8154 Power Distribution Fuse 29 Fuse 29 - protects the following circuits: ^ Flip Window Relay ^ Hybrid Cooling Fan Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8155 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Engine Fuse Module Fuse Block: Locations Engine Fuse Module Engine View The Engine Fuse Module is located near the power distribution box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Engine Fuse Module > Page 8160 Fuse Block: Locations Junction Box/Fuse Relay Panel Junction Box Fuse/Relay Panel (Part 1 Of 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Engine Fuse Module > Page 8161 Instrument Panel View The Junction Box/Fuse Relay Panel is located under left side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8164 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8165 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8166 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8167 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8168 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8169 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8170 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8171 Fuse Block: Connector Views Junction Box/Fuse Panel (C243) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8172 Junction Box/Fuse Panel (C242) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8173 Fuse Block: Electrical Diagrams Circuit-to-Fuse Cross Reference 4 Wheel Anti-Lock Brake System Module ........................................................................................... ..................................................................... Fuse 14 Accessory Delay Relay .................................... .......................................................................................................................................................... Fuse 25 Air Bag Diagnostic Monitor .................................................................................................... .................................................................................... Fuse 2 Air Suspension Service Switch ........... .............................................................................................................................................................. ........... Fuse 4 Air Suspension Solid State Compressor Relay .......................................................................................................................................................... Fuse 15 All Lock Relays ...................................................................................................................... ..................................................................................... Fuse 3 All Unlock Relays ............................... .............................................................................................................................................................. ........... Fuse 3 Auxiliary A/C Relay ...................................................................................................... ............................................................................................ Fuse 13 Compact Disc Changer ............ .............................................................................................................................................................. ...................... Fuse 6 Console Auxiliary Power Socket ....................................................................... ........................................................................................................ Fuse 11 Daytime Running Lamps Module ..................................................................................................................................... ........................................... Fuse 9 Drover's Unlock Relay ................................................................. ................................................................................................................................ Fuse 3 Engine Fuse Module (Fuse 1) ......................................................................................................................... ........................................................... Fuse 24 Engine Fuse Module (Fuse 2) ................................... ................................................................................................................................................. Fuse 16 Engine Fuse Module (Fuse 3) ........................................................................................................ .............................................................................. Fuse 6 Engine Fuse Module (Fuse 5) .................. .............................................................................................................................................................. ...... Fuse 6 Flip Window Relay ............................................................................................................ ........................................................................................ Fuse 29 Fog Lamp Relay ........................... .............................................................................................................................................................. .................. Fuse 9 Fuel Pump Relay .................................................................................................. ...................................................................................................... Fuse 19 Headlamp Relay ............. .............................................................................................................................................................. ................................ Fuse 8 Heated Grid Relay .................................................................................. ................................................................................................................... Fuse 27 Horn Relay ......... .............................................................................................................................................................. ............................................ Fuse 5 Hybrid Cooling Fan Relay ........................................................... .............................................................................................................................. Fuse 29 Ignition Switch .................................................................................................................................................. ................................................ Fuse 20 & 21 Instrument Panel (I/P) Auxiliary Power Socket ......................................................................................................................................................... Fuse 10 I/P Blower Relay .................................................................................................................... .................................................................................... Fuse 23 Junction Box Fuse/Relay Panel Battery Feed ............................................................................................................................................................ Fuse 22 Junction Box Fuse/Relay Panel ............................................................................................. ........................................................................... Fuse 25 & 27 Main Light Switch .............................. .............................................................................................................................................................. .... Fuse 7 & 8 Multi-Function Switch ................................................................................................... .............................................................................................. Fuse 8 Park Lamp Relay ...................... .............................................................................................................................................................. ..................... Fuse 7 PCM Power Relay ............................................................................................. ........................................................................................................ Fuse 24 Power Seat Control Switch .................................................................................................................................................. ...................................... Fuse 18 Premium Sound Amplifier ............................................................... ............................................................................................................................ Fuse 6 Radio .......... .............................................................................................................................................................. ................................................... Fuse 6 Rear Integrated Control Panel ............................................. ......................................................................................................................................... Fuse 6 Rear Wiper Down Motor Relay ..................................................................................................................... ............................................................ Fuse 12 Rear Wiper Up Motor Relay ..................................... ................................................................................................................................................. Fuse 12 Shift On The Fly Relay ................................................................................................................... ........................................................................... Fuse 17 Sub-Woofer Power .................................... .............................................................................................................................................................. .... Fuse 6 Trailer Electronic Brake Controller ...................................................................................... ..................................................................................... Fuse 28 Trailer Tow Backup Lamp Relay ..... .............................................................................................................................................................. ............. Fuse 1 Trailer Tow Battery Charge Relay ............................................................................. ................................................................................................ Fuse 16 Trailer Tow Running Lamp Relay ................................................................................................................................................... ............................ Fuse 1 Transfer Case Shift Relay .......................................................................... ................................................................................................................ Fuse 17 Fuse 1 - Trailer Backup and Running Lamp Relays Fuse 1 - protects the following circuits: ^ Trailer Tow Running Lamp Relay ^ Trailer Tow Backup Lamp Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8174 Power Distribution Fuse 2 - Air Bag Diagnostic Monitor Fuse 2 - protects the following circuits: ^ Air Bag Diagnostic Monitor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8175 Power Distribution Fuse 3 - All Unlock/Lock Relays, Drivers' Unlock Relay Fuse 3 - protects the following circuits: ^ All Unlock Relay ^ All Lock Relay ^ Driver's Unlock Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8176 Power Distribution Fuse 4 - Air Suspension Service Switch Fuse 4 - protects the following circuits: ^ Air Suspension Service Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8177 Power Distribution Fuse 5 - Horn Relay Fuse 5 - protects the following circuits: ^ Horn Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8178 Power Distribution Fuse 6 - Var. Sound Sys. Components, Eng. Fuse Mdl Fuses 3 & 5 Fuse 6 - protects the following circuits: ^ Radio ^ Premium Sound Amplifier ^ Compact Disc Changer ^ Rear Integrated Control Panel Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8179 ^ Engine Fuse Module Fuse 3 ^ Engine Fuse Module Fuse 5 ^ Sub-Woofer Power Power Distribution Fuse 7 - Main Light Switch, Park Lamp Relay Fuse 7 - protects the following circuits: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8180 ^ Main Light Switch ^ Park Lamp Relay Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8181 Power Distribution Fuse 8 - Main Light Switch, Headlamp Relay, Multi-function Sw Fuse 8 - protects the following circuits: ^ Main Light Switch ^ Headlamp Relay ^ Multi-function Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8182 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8183 Power Distribution Fuse 9 - DRL Module, Fog Lamp Relay Fuse 9 - protects the following circuits: ^ Daytime Running Lamps Module ^ Fog Lamp Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8184 Power Distribution Fuse 10 - Instrument Panel Aux. Power Socket Fuse 10 - protects the following circuits: ^ Instrument Panel Auxiliary Power Socket Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8185 Power Distribution Fuse 11 - Console Aux. Power Socket Fuse 11 - protects the following circuits: ^ Console Auxiliary Power Socket Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8186 Power Distribution Fuse 12 - Rear Wiper Up And Down Motor Relays Fuse 12 - protects the following circuits: ^ Rear Wiper Up Motor Relay ^ Rear Wiper Down Motor Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8187 Power Distribution Fuse 13 - Auxiliary A/C Relay Fuse 13 - protects the following circuits: ^ Auxiliary A/C Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8188 Power Distribution Fuse 14 - 4 Wheel Anti-Lock Brake System Module Fuse 14 - protects the following circuits: ^ 4 Wheel Anti-Lock Brake System Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8189 Power Distribution Fuse 15 - Air Suspension Solid State Compressor Relay Fuse 15 - protects the following circuits: ^ Air Suspension Solid State Compressor Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8190 Power Distribution Fuse 16 - Trailer Tow Bttry Charge Relay, Eng Fuse Module Fuse2 Fuse 16 - protects the following circuits: ^ Trailer Tow Battery Charge Relay ^ Engine Fuse Module Fuse 2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8191 Power Distribution Fuse 17 - Shift-On-The-Fly Relay, Tranfer Case Shift Relay Fuse 17 - protects the following circuits: ^ Shift On The Fly Relay ^ Transfer Case Shift Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8192 Power Distribution Fuse 18 - Power Seat Control Switch Fuse 18 - protects the following circuits: ^ Power Seat Control Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8193 Power Distribution Fuse 19 - Fuel Pump Relay Fuse 19 - protects the following circuits: ^ Fuel Pump Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8194 Power Distribution Fuse 20 - Ignition Switch Fuse 20 - protects the following circuits: ^ Ignition Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8195 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8196 Power Distribution Fuse 21 - Ignition Switch Fuse 21 - protects the following circuits: ^ Ignition Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8197 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8198 Power Distribution Fuse 22 - Junction Box Fuse/Relay Panel Battery Feed Fuse 22 - protects the following circuits: ^ Junction Box Fuse/Relay Panel Battery Feed Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8199 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8200 Power Distribution Fuse 23 - Instrument Panel Blower Relay Fuse 23 - protects the following circuits: ^ Instrument Panel Blower Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8201 Power Distribution Fuse 24 - PCM Power Relay, Engine Fuse Module Fuse 1 Fuse 24 - protects the following circuits: ^ PCM Power Relay ^ Engine Fuse Module Fuse 1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8202 Power Distribution Fuse 25 - Junction Box Fuse/Relay Panel, Accessory Delay Relay Fuse 25 - protects the following circuits: ^ Junction Box Fuse/Relay Panel ^ Accessory Delay Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8203 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8204 Power Distribution Fuse 27 - Junction Box Fuse/Relay Panel, Heated Grid Relay Fuse 27 - protects the following circuits: ^ Junction Box Fuse/Relay Panel ^ Heated Grid Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8205 Power Distribution Fuse 28 - Trailer Electronic Brake Controller Fuse 28 - protects the following circuits: ^ Trailer Electronic Brake Controller Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8206 Power Distribution Fuse 29 - Flip Window Relay, Hybrid Cooling Fan Relay Fuse 29 - protects the following circuits: ^ Flip Window Relay ^ Hybrid Cooling Fan Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8207 Power Distribution Circuit-to-Fuse Cross Reference 4 Wheel Air Suspension Module ......................................................................................................... ........................................................................ Fuse 6 4 Wheel Air Suspension ................................. ........................................................................................................................................................... Fuse 20 4 Wheel Anti-Lock Brake System Module ............................................................................. ................................................................................... Fuse 25 4 Wheel Anti-Lock Brake System Relay ................................................................................................................................................... ................ Fuse 25 4X4 Center Axle Disconnect Solenoid .................................................................. .................................................................................................... Fuse 23 Air Bag Diagnostic Monitor .............................................................................................................................................................. ............... Fuse 19 & 22 Autolamp Module .......................................................................................... ..................................................................................................... Fuse 4 & 29 Auxiliary A/C Control Module ................................................................................................................................................. ................................ Fuse 23 Auxiliary A/C Mode Actuator ................................................................. .................................................................................................................. Fuse 23 Auxiliary A/C Relay ................................................................................................................................................... ................................................. Fuse 7 Battery Saver Relay ............................................................... .................................................................................................................................... Fuse 14 Blend Door Actuator ...................................................................................................................................... ............................................................. Fuse 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8208 Brake On/Off Switch ............................................................................................................................ ..................................................................... Fuse 13 Brake Pressure Switch .................................... ........................................................................................................................................................... Fuse 13 Cigar Lighter .......................................................................................................................... ...................................................................................... Fuse 3 Coil On Plugs .................................... .............................................................................................................................................................. ........... Fuse 30 Compass Sensor ....................................................................................................... .................................................................................................... Fuse 6 Console Blower Motor ........ .............................................................................................................................................................. .......................... Fuse 7 Data Link Connector ..................................................................................... ............................................................................................................. Fuse 12 Daytime Running Lamps Module ..................................................................................................................................... ............................. Fuse 5,16 & 26 Digital Transmission Range Sensor ............................................. ....................................................................................................................... Fuse 5 & 21 Electronic Variable Orifice Module ....................................................................................................................... ..................................................... Fuse 5 Flasher Relay .................................................................... ........................................................................................................................................... Fuse 1 Fog Lamp Relay .................................................................................................................................. ....................................................................... Fuse 27 Function Selector Switch ............................... ................................................................................................................................................... Fuse 23 & 24 Generic Electronic Module ..................................................................................................... .................................................................. Fuse 6,18,15 & 20 Headlamp Relay ................................. .............................................................................................................................................................. ............ Fuse 4 Heated Backlight Switch ............................................................................................. ............................................................................................... Fuse 17 Heated Grid Relay ................. .............................................................................................................................................................. ........................ Fuse 6 Heater-A/C Control Assembly ........................................................................ ............................................................................................................. Fuse 5 High Beam Headlamps .......................................................................................................................................... .................................................... Fuse 16 Ignition Coil ....................................................................... ........................................................................................................................................ Fuse 30 Instrument Cluster ............................................................................................................................... ........................................................... Fuse 2,19 & 29 Instrument Cluster (Without Daytime Running Lamps) ............................................................................................................................................ Fuse 16 Instrument Illumination .......................................................................................................... .................................................................................... Fuse 18 Interior Lamp Relay .......................... .............................................................................................................................................................. ........... Fuse 14 Junction Box Fuse/Relay Panel ................................................................................. ................................................................................................ Fuse 21 Junction Box Fuse Relay Panel Fuse 20 ..................................................................................................................................... ............................... Fuse 21 Left Headlamp ....................................................................................... .................................................................................................................... Fuse 28 Left Power/Heated Signal Mirror ................................................................................................................ .............................................................. Fuse 17 Main Light Switch ................................................... ...................................................................................................................................... Fuse 8,18 & 27 Overhead Trip Computer Module ................................................................................................... ...................................................................... Fuse 2 & 6 PCM Power Diode ...................................... .............................................................................................................................................................. . Fuse 30 Park Lamp Relay ................................................................................................................. ........................................................................................ Fuse 4 Passive Anti-Theft System Module . .............................................................................................................................................................. ............ Fuse 15 Power Mirror Switch ................................................................................................. .................................................................................................. Fuse 4 Radio Noise Capacitor .......... .............................................................................................................................................................. ....................... Fuse 30 Radio ............................................................................................................. .............................................................................................................. Fuse 8 Rear Integrated Control Panel ....................................................................................................................................... ............................................. Fuse 23 Rear Wiper Pump Relay .......................................................... .................................................................................................................................. Fuse 11 Recirculation Vacuum Solenoid ........................................................................................................... ..................................................................... Fuse 23 Remote Anti-Theft Personality Module ............ .................................................................................................................................................... Fuse 4 & 8 Right Headlamp ......................................................................................................................... ................................................................................ Fuse 26 Right Power/Heated Signal Mirror ........ .............................................................................................................................................................. ...... Fuse 17 Shift Lock Actuator ......................................................................................................... ............................................................................................ Fuse 6 Speed Control Servo/Amplifier Assembly ............................................................................................................................................. ...................... Fuse 5 Steering Wheel Rotation Sensor ...................................................................... ............................................................................................................ Fuse 6 Trailer Tow Battery Charge Relay ....................................................................................................................................... ...................................... Fuse 23 Transmission Control Switch .......................................................... ........................................................................................................................... Fuse 29 Washer Pump Relay ......................................................................................................................................... .......................................................... Fuse 11 Windshield Wiper Motor ............................................. .............................................................................................................................................. Fuse 11 Wiper High/Low Relay ......................................................................................................................... ..................................................................... Fuse 11 Wiper Run/Park Relay ..................................... .......................................................................................................................................................... Fuse 11 Fuse 1 - Flasher Relay Fuse 1 - protects the following circuits: ^ Flasher Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8209 Power Distribution Fuse 2 - Instrument Cluster, OH Trip Computer Fuse 2 - protects the following circuits: ^ Instrument Cluster ^ Overhead Trip Computer Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8210 Power Distribution Fuse 3 - Cigar Lighter Fuse 3 - protects the following circuits: ^ Cigar Lighter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8211 Power Distribution Fuse 4 - Park & Hdlp Relays, Autolamp & RAP Mdl, Pwr Mirror Sw. Fuse 4 - protects the following circuits: ^ Park Lamp Relay ^ Headlamp Relay ^ Autolamp Module ^ Remote Anti-Theft Personality Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8212 ^ Power Mirror Switch Power Distribution Fuse 5 - TRS, DRL Mdl, Spd Ctrl Servo/Amp Assy, HVAC Ctrl Assy Fuse 5 - protects the following circuits: ^ Digital Transmission Range Sensor ^ Daytime Running Lamps Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8213 ^ Speed Control Servo/Amplifier Assembly ^ Heater-A/C Control Assembly ^ Blend Door Actuator ^ Electronic Variable Orifice Module Power Distribution Fuse 6 - Shift Lock, GEM, Air Susp. Mdl, OH Trip Cmptr, Compass Fuse 6 - protects the following circuits: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8214 ^ Shift Lock Actuator ^ Generic Electronic Module ^ 4 Wheel Air Suspension Module ^ Compass Sensor ^ Steering Wheel Rotation Sensor ^ Heated Grid Relay ^ Overhead Trip Computer Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8215 Power Distribution Power Distribution Fuse 7 - Aux. A/C Relay, Blower Motor Fuse 7 - protects the following circuits: ^ Auxiliary A/C Relay ^ Console Blower Motor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8216 Power Distribution Fuse 8 - Radio, Main Light Switch, RAP Module Fuse 8 - protects the following circuits: ^ Radio ^ Main Light Switch ^ Remote Anti-Theft Personality Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8217 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8218 Power Distribution Fuse 11 - Washer Pump, Wiper Run/Park Hi/Lo Relays, Wiper Motor Fuse 11 - protects the following circuits: ^ Washer Pump Relay ^ Wiper Run/Park Relay ^ Wiper High/Low Relay ^ Windshield Wiper Motor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8219 ^ Rear Wiper Pump Relay Power Distribution Fuse 12 - Data Link Connector Fuse 12 - protects the following circuits: ^ Data Link Connector Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8220 Power Distribution Fuse 13 - Brake Pedal Position and Brake Pressure Switches Fuse 13 - protects the following circuits: ^ Brake On/Off Switch ^ Brake Pressure Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8221 Power Distribution Fuse 14 - Battery Saver and Interior Lamp Relays Fuse 14 - protects the following circuits: ^ Battery Saver Relay ^ Interior Lamp Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8222 Power Distribution Fuse 15 - GEM and RAP Modules Fuse 15 - protects the following circuits: ^ Generic Electronic Module ^ Passive Anti-Theft System Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8223 Power Distribution Fuse 16 - Inst. Cluster, DRL Module, High Beam Headlamps Fuse 16 - protects the following circuits: ^ Instrument Cluster (Without Daytime Running Lamps) ^ Daytime Running Lamps Module ^ High Beam Headlamps Power Source Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8224 Power is Supplied Through Multi-Function Switch Power Distribution Fuse 17 - Htd Backlight Sw, Left & Right Pwr/Htd Signal Mirrors Fuse 17 - protects the following circuits: ^ Heated Backlight Switch ^ Left Power/Heated Signal Mirror Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8225 ^ Right Power/Heated Signal Mirror Power Distribution Fuse 18 - Main Light Sw, GEM, Instr. Illumination Fuse 18 - protects the following circuits: ^ Main Light Switch ^ Generic Electronic Module ^ Instrument Illumination Power Source Power is Supplied Through Main Light Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8226 Power Distribution Fuse 19 - Instrument Cluster, Air Bag Diagnostic Monitor Fuse 19 - protects the following circuits: ^ Instrument Cluster ^ Air Bag Diagnostic Monitor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8227 Power Distribution Fuse 20 - 4 Wheel Air Suspension, GEM Fuse 20 - protects the following circuits: ^ 4 Wheel Air Suspension ^ Generic Electronic Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8228 Power Distribution Fuse 21 - Digital Trans. Range Snsr, JB Fuse/Relay Pnl Fuse 20 Fuse 21 - protects the following circuits: ^ Digital Transmission Range Sensor ^ Junction Box Fuse/Relay Panel Fuse 20 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8229 Power Distribution Fuse 22 - Air Bag Diagnostic Monitor Fuse 22 - protects the following circuits: ^ Air Bag Diagnostic Monitor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8230 Power Distribution Fuse 23 - Tow Btty Chg Relay, 4X4 Ctr Axle Disc, Func Selector Fuse 23 - protects the following circuits: ^ Trailer Tow Battery Charge Relay ^ 4X4 Center Axle Disconnect Solenoid Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8231 ^ Function Selector Switch ^ Rear Integrated Control Panel ^ Recirculation Vacuum Solenoid ^ Auxiliary A/C Mode Actuator ^ Auxiliary A/C Control Module Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8232 Fuse 24 - Function Selector Switch Fuse 24 - protects the following circuits: ^ Function Selector Switch Power Distribution Fuse 25 - 4WABS Module and 4WABS Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8233 Fuse 25 - protects the following circuits: ^ 4 Wheel Anti-Lock Brake System Module ^ 4 Wheel Anti-Lock Brake System Relay Power Distribution Fuse 26 - DRL Module and Right Headlamp Fuse 26 - protects the following circuits: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8234 ^ Daytime Running Lamps Module ^ Right Headlamp Power Source Power is Supplied Through Multi-Function Switch Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8235 Fuse 27 - Main Light Switch and Fog Lamp Relay Fuse 27 - protects the following circuits: ^ Main Light Switch ^ Fog Lamp Relay Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8236 Fuse 28 - Left Headlamp Fuse 28 - protects the following circuits: ^ Left Headlamp Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8237 Fuse 29 - Autolamp Module, Instrument Cluster, Trans Ctrl Sw Fuse 29 - protects the following circuits: ^ Autolamp Module ^ Instrument Cluster ^ Transmission Control Switch Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8238 Fuse 30 - Radio Noise Cap., Ignition Coil, PCM Pwr Diode... Fuse 30 - protects the following circuits: ^ Radio Noise Capacitor ^ Ignition Coil ^ PCM Power Diode ^ Coil On Plugs Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8239 Power Distribution Circuit-to-Fuse Cross Reference Compact Disc Changer ....................................................................................................................... ......................................................................... Fuse 3 Powertrain Control Module ............................ ............................................................................................................................................................. Fuse 1 Premium Sound Amplifier ........................................................................................................ ................................................................................... Fuse 5 Radio ................................................... .............................................................................................................................................................. .......... Fuse 3 Rear Integrated Control Panel ...................................................................................... ................................................................................................ Fuse 3 Sub-Woofer Power ................. .............................................................................................................................................................. ....................... Fuse 5 Trailer Tow Left Turn Relay ............................................................................. .......................................................................................................... Fuse 2 Trailer Tow Right Turn Relay ................................................................................................................................................... .................................. Fuse 2 Fuse 1 - Powertrain Control Module Fuse 1 - protects the following circuits: ^ Powertrain Control Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8240 Power Distribution Fuse 2 - Trailer Turn Signal Relays Fuse 2 - protects the following circuits: ^ Trailer Tow Left Turn Relay ^ Trailer Tow Right Turn Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8241 Power Distribution Fuse 3 - Radio, Rear Int. Control Panel, CD Changer Fuse 3 - protects the following circuits: ^ Radio ^ Rear Integrated Control Panel ^ Compact Disc Changer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8242 Power Distribution Fuse 5 - Subwoofer, Prem. Sound Amplifier Fuse 5 - protects the following circuits: ^ Sub-Woofer Power ^ Premium Sound Amplifier Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8243 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8244 Engine Fuse Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8245 Junction Box Fuse/Relay Panel (Part 1 Of 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8246 Junction Box Fuse/Relay Panel (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8247 Power Distribution Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8248 Primary Battery Fuses Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 In-Line Connector Faces - C119 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8253 In-Line Connector Faces - C120 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8254 In-Line Connector Faces - C148 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8255 In-Line Connector Faces - C149 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8256 Multiple Junction Connector: Diagrams In-Line Connector Faces - C119 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8257 In-Line Connector Faces - C120 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8258 In-Line Connector Faces - C148 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8259 In-Line Connector Faces - C149 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8260 In-Line Connector Faces - C158 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8261 In-Line Connector Faces - C159 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8262 In-Line Connector Faces - C160 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8263 In-Line Connector Faces - C172 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8264 In-Line Connector Faces - C203 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8265 In-Line Connector Faces - C206 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8266 In-Line Connector Faces - C210 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8267 In-Line Connector Faces - C232 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8268 In-Line Connector Faces - C247 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8269 In-Line Connector Faces - C248 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8270 In-Line Connector Faces - C253 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8271 In-Line Connector Faces - C269 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8272 In-Line Connector Faces - C271 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8273 In-Line Connector Faces - C403 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8274 In-Line Connector Faces - C403 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8275 In-Line Connector Faces - C429 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8276 In-Line Connector Faces - C431 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8277 In-Line Connector Faces - C432 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8278 In-Line Connector Faces - C455 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8279 In-Line Connector Faces - C455 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8280 In-Line Connector Faces - C917 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8281 In-Line Connector Faces - C921 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8282 In-Line Connector Faces - C921 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8283 In-Line Connector Faces - C921 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8284 In-Line Connector Faces - C922 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8285 In-Line Connector Faces - C941 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay Power Distribution Relay: Locations Trailer Tow Backup Lamp Relay Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 8290 Power Distribution Relay Box The Trailer Tow Backup Lamp Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 8291 Power Distribution Relay: Locations Trailer Tow Battery Charge Relay Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 8292 Power Distribution Relay Box The Trailer Tow Battery Charge Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 8293 Power Distribution Relay: Locations Trailer Tow Left Turn Relay Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 8294 Power Distribution Relay Box The Trailer Tow Left Turn Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 8295 Power Distribution Relay: Locations Trailer Tow Right Turn Relay Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 8296 Power Distribution Relay Box The Trailer Tow Right Turn Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 8297 Power Distribution Relay: Locations Trailer Tow Running Lamp Relay Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 8298 Power Distribution Relay Box The Trailer Tow Running Lamp Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay Power Distribution Relay: Locations Trailer Tow Backup Lamp Relay Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 8304 Power Distribution Relay Box The Trailer Tow Backup Lamp Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 8305 Power Distribution Relay: Locations Trailer Tow Battery Charge Relay Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 8306 Power Distribution Relay Box The Trailer Tow Battery Charge Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 8307 Power Distribution Relay: Locations Trailer Tow Left Turn Relay Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 8308 Power Distribution Relay Box The Trailer Tow Left Turn Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 8309 Power Distribution Relay: Locations Trailer Tow Right Turn Relay Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 8310 Power Distribution Relay Box The Trailer Tow Right Turn Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 8311 Power Distribution Relay: Locations Trailer Tow Running Lamp Relay Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 8312 Power Distribution Relay Box The Trailer Tow Running Lamp Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Blower/Flasher Relay Block Relay Box: Locations Blower/Flasher Relay Block Instrument Panel View The Blower/Flasher Relay Block is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Blower/Flasher Relay Block > Page 8317 Relay Box: Locations Lock Relays Body View The Lock Relays are located behind right side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Blower/Flasher Relay Block > Page 8318 Relay Box: Locations Regular Production Option Relay Block Instrument Panel View The Regular Production Option Relay Block is located in dash, above passenger air bag. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block Power/Flasher Relay Block Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 8321 Lock Relays Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 8322 Power Distribution Relay Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 8323 RPO Relay Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Blower/Flasher Relay Block Relay Box: Locations Blower/Flasher Relay Block Instrument Panel View The Blower/Flasher Relay Block is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Blower/Flasher Relay Block > Page 8328 Relay Box: Locations Lock Relays Body View The Lock Relays are located behind right side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Blower/Flasher Relay Block > Page 8329 Relay Box: Locations Regular Production Option Relay Block Instrument Panel View The Regular Production Option Relay Block is located in dash, above passenger air bag. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block Power/Flasher Relay Block Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 8332 Lock Relays Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 8333 Power Distribution Relay Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 8334 RPO Relay Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Electrical Diode - Identification and Replacement Diode: Technical Service Bulletins Electrical Diode - Identification and Replacement Article No. 96-24-6 11/18/96 WIRING - ELECTRICAL DIODE IDENTIFICATION AND SERVICE REPLACEMENTS FORD: 1984-86 LTD 1984-88 EXP 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1984-86 MARQUIS 1984-87 LYNX 1984-92 MARK VII 1984-94 TOPAZ 1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1983-97 RANGER 1984-90 BRONCO II 1984-97 ECONOLINE, F-150-350 SERIES 1986-97 AEROSTAR 1991-97 EXPLORER 1995-97 WINDSTAR MEDIUM/HEAVY TRUCK: 1984-91 C SERIES, CL-CLT-9000 SERIES 1984-97 F & B SERIES, L SERIES 1986-97 CARGO SERIES 1996-97 AEROMAX, LOUISVILLE This TSB article is being republished in its entirety to update the applicable model years. ISSUE: Electrical system concerns that are due to diode failure may be serviced with an approved Ford service diode. Some electrical diodes used in early production vehicles are color coded for the purpose of size identification while others are stamped with a manufacture number. All Ford service diodes and current production diodes are identified by manufacture number. ACTION: If service is required, refer to the appropriate model/year Electrical and Vacuum Troubleshooting Manual (EVTM) to determine the size and location of the diode(s). Refer to the following Electrical Diode Application Chart for the correct service part number. NOTE: IF THE DIODE REQUIRING REPLACEMENT DOES NOT HAVE THE SAME RATING AS LISTED IN THE APPLICATION CHART, USE THE NEXT HIGHER RATED DIODE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Electrical Diode - Identification and Replacement > Page 8340 ELECTRICAL DIODE APPLICATION CHART PART NUMBER PART NAME E8DZ-10C912-A Diode - 1.0 Amp - 400V E8DZ-10C912-B Diode - 6.0 Amp - 400V OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 89-2-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 2770 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 8349 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 8350 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 8351 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 8352 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 8353 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 8354 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 8355 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 8356 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 8362 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 8363 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 8364 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 8365 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 8366 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 8367 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 8368 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 8369 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8374 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8375 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8376 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8377 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8378 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8379 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8380 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8381 Fuse: Electrical Diagrams Circuit-to-Fuse Cross Reference Compact Disc Changer ....................................................................................................................... ......................................................................... Fuse 3 Powertrain Control Module ............................ ............................................................................................................................................................. Fuse 1 Premium Sound Amplifier ........................................................................................................ ................................................................................... Fuse 5 Radio ................................................... .............................................................................................................................................................. .......... Fuse 3 Rear Integrated Control Panel ...................................................................................... ................................................................................................ Fuse 3 Sub-Woofer Power ................. .............................................................................................................................................................. ....................... Fuse 5 Trailer Tow Left Turn Relay ............................................................................. .......................................................................................................... Fuse 2 Trailer Tow Right Turn Relay ................................................................................................................................................... .................................. Fuse 2 Fuse 1 Fuse 1 - protects the following circuits: ^ Powertrain Control Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8382 Power Distribution Fuse 2 Fuse 2 - protects the following circuits: ^ Trailer Tow Left Turn Relay ^ Trailer Tow Right Turn Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8383 Power Distribution Fuse 3 Fuse 3 - protects the following circuits: ^ Radio ^ Rear Integrated Control Panel ^ Compact Disc Changer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8384 Power Distribution Fuse 5 Fuse 5 - protects the following circuits: ^ Sub-Woofer Power ^ Premium Sound Amplifier Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8385 Power Distribution Circuit-to-Fuse Cross Reference 4 Wheel Air Suspension Module ......................................................................................................... ........................................................................ Fuse 6 4 Wheel Air Suspension ................................. ........................................................................................................................................................... Fuse 20 4 Wheel Anti-Lock Brake System Module ............................................................................. ................................................................................... Fuse 25 4 Wheel Anti-Lock Brake System Relay ................................................................................................................................................... ................ Fuse 25 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8386 4X4 Center Axle Disconnect Solenoid ................................................................................................. ..................................................................... Fuse 23 Air Bag Diagnostic Monitor .............................. ............................................................................................................................................... Fuse 19 & 22 Autolamp Module ........................................................................................................................ ....................................................................... Fuse 4 & 29 Auxiliary A/C Control Module .................. .............................................................................................................................................................. . Fuse 23 Auxiliary A/C Mode Actuator ................................................................................................ ................................................................................... Fuse 23 Auxiliary A/C Relay ............................ .............................................................................................................................................................. .......... Fuse 7 Battery Saver Relay ...................................................................................................... ............................................................................................. Fuse 14 Blend Door Actuator ................ .............................................................................................................................................................. ..................... Fuse 5 Brake On/Off Switch .......................................................................................... ....................................................................................................... Fuse 13 Brake Pressure Switch .. .............................................................................................................................................................. ............................... Fuse 13 Cigar Lighter .......................................................................................... ...................................................................................................................... Fuse 3 Coil On Plugs .... .............................................................................................................................................................. ........................................... Fuse 30 Compass Sensor ....................................................................... .................................................................................................................................... Fuse 6 Console Blower Motor ......................................................................................................................... ....................................................................... Fuse 7 Data Link Connector ........................................ .......................................................................................................................................................... Fuse 12 Daytime Running Lamps Module .......................................................................................... ........................................................................ Fuse 5,16 & 26 Digital Transmission Range Sensor .. .............................................................................................................................................................. .... Fuse 5 & 21 Electronic Variable Orifice Module ............................................................................. ............................................................................................... Fuse 5 Flasher Relay .......................... .............................................................................................................................................................. ....................... Fuse 1 Fog Lamp Relay .............................................................................................. ........................................................................................................... Fuse 27 Function Selector Switch .................................................................................................................................................. ................................ Fuse 23 & 24 Generic Electronic Module ........................................................... ............................................................................................................ Fuse 6,18,15 & 20 Headlamp Relay ................................................................................................................................................... ........................................................ Fuse 4 Heated Backlight Switch ................................................. ........................................................................................................................................... Fuse 17 Heated Grid Relay ............................................................................................................................... ........................................................................ Fuse 6 Heater-A/C Control Assembly ........................ ............................................................................................................................................................. Fuse 5 High Beam Headlamps ............................................................................................................ .................................................................................. Fuse 16 Ignition Coil ......................................... .............................................................................................................................................................. ........ Fuse 30 Instrument Cluster ........................................................................................................ .................................................................................. Fuse 2,19 & 29 Instrument Cluster (Without Daytime Running Lamps) ............................................................................................................................................ Fuse 16 Instrument Illumination ........................................................................................................................ ...................................................................... Fuse 18 Interior Lamp Relay ........................................ ........................................................................................................................................................... Fuse 14 Junction Box Fuse/Relay Panel ............................................................................................. .................................................................................... Fuse 21 Junction Box Fuse Relay Panel Fuse 20 ......................................................................................................................................................... ........... Fuse 21 Left Headlamp ........................................................................................................... ................................................................................................ Fuse 28 Left Power/Heated Signal Mirror ................................................................................................................................................... ........................... Fuse 17 Main Light Switch ...................................................................................... ................................................................................................... Fuse 8,18 & 27 Overhead Trip Computer Module ................................................................................................................................ ......................................... Fuse 2 & 6 PCM Power Diode ................................................................... .................................................................................................................................. Fuse 30 Park Lamp Relay ......................................................................................................................................... ................................................................ Fuse 4 Passive Anti-Theft System Module ......................... .................................................................................................................................................. Fuse 15 Power Mirror Switch ....................................................................................................................... ............................................................................ Fuse 4 Radio Noise Capacitor ................................ .............................................................................................................................................................. . Fuse 30 Radio ................................................................................................................................... ........................................................................................ Fuse 8 Rear Integrated Control Panel ........ .............................................................................................................................................................. .............. Fuse 23 Rear Wiper Pump Relay ......................................................................................... ................................................................................................... Fuse 11 Recirculation Vacuum Solenoid ............................................................................................................................................... ................................. Fuse 23 Remote Anti-Theft Personality Module ................................................ ................................................................................................................ Fuse 4 & 8 Right Headlamp .............................................................................................................................................................. ........................................... Fuse 26 Right Power/Heated Signal Mirror ............................................. ............................................................................................................................... Fuse 17 Shift Lock Actuator ............................................................................................................................................... ...................................................... Fuse 6 Speed Control Servo/Amplifier Assembly ......................... .......................................................................................................................................... Fuse 5 Steering Wheel Rotation Sensor ......................................................................................................... ......................................................................... Fuse 6 Trailer Tow Battery Charge Relay ................. ............................................................................................................................................................ Fuse 23 Transmission Control Switch ................................................................................................. .................................................................................... Fuse 29 Washer Pump Relay ......................... .............................................................................................................................................................. ............ Fuse 11 Windshield Wiper Motor ........................................................................................... ................................................................................................ Fuse 11 Wiper High/Low Relay .......... .............................................................................................................................................................. ...................... Fuse 11 Wiper Run/Park Relay .................................................................................... ........................................................................................................... Fuse 11 Fuse 1 Fuse 1 - protects the following circuits: ^ Flasher Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8387 Power Distribution Fuse 2 Fuse 2 - protects the following circuits: ^ Instrument Cluster ^ Overhead Trip Computer Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8388 Power Distribution Fuse 3 Fuse 3 - protects the following circuits: ^ Cigar Lighter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8389 Power Distribution Fuse 4 Fuse 4 - protects the following circuits: ^ Park Lamp Relay ^ Headlamp Relay ^ Autolamp Module ^ Remote Anti-Theft Personality Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8390 ^ Power Mirror Switch Power Distribution Fuse 5 Fuse 5 - protects the following circuits: ^ Digital Transmission Range Sensor ^ Daytime Running Lamps Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8391 ^ Speed Control Servo/Amplifier Assembly ^ Heater-A/C Control Assembly ^ Blend Door Actuator ^ Electronic Variable Orifice Module Power Distribution Fuse 6 Fuse 6 - protects the following circuits: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8392 ^ Shift Lock Actuator ^ Generic Electronic Module ^ 4 Wheel Air Suspension Module ^ Compass Sensor ^ Steering Wheel Rotation Sensor ^ Heated Grid Relay ^ Overhead Trip Computer Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8393 Power Distribution Power Distribution Fuse 7 Fuse 7 - protects the following circuits: ^ Auxiliary A/C Relay ^ Console Blower Motor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8394 Power Distribution Fuse 8 Fuse 8 - protects the following circuits: ^ Radio ^ Main Light Switch ^ Remote Anti-Theft Personality Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8395 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8396 Power Distribution Fuse 11 Fuse 11 - protects the following circuits: ^ Washer Pump Relay ^ Wiper Run/Park Relay ^ Wiper High/Low Relay ^ Windshield Wiper Motor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8397 ^ Rear Wiper Pump Relay Power Distribution Fuse 12 Fuse 12 - protects the following circuits: ^ Data Link Connector Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8398 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: ^ Brake On/Off Switch ^ Brake Pressure Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8399 Power Distribution Fuse 14 Fuse 14 - protects the following circuits: ^ Battery Saver Relay ^ Interior Lamp Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8400 Power Distribution Fuse 15 Fuse 15 - protects the following circuits: ^ Generic Electronic Module ^ Passive Anti-Theft System Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8401 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: ^ Instrument Cluster (Without Daytime Running Lamps) ^ Daytime Running Lamps Module ^ High Beam Headlamps Power Source Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8402 Power is Supplied Through Multi-Function Switch Power Distribution Fuse 17 Fuse 17 - protects the following circuits: ^ Heated Backlight Switch ^ Left Power/Heated Signal Mirror Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8403 ^ Right Power/Heated Signal Mirror Power Distribution Fuse 18 Fuse 18 - protects the following circuits: ^ Main Light Switch ^ Generic Electronic Module ^ Instrument Illumination Power Source Power is Supplied Through Main Light Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8404 Power Distribution Fuse 19 Fuse 19 - protects the following circuits: ^ Instrument Cluster ^ Air Bag Diagnostic Monitor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8405 Power Distribution Fuse 20 Fuse 20 - protects the following circuits: ^ 4 Wheel Air Suspension ^ Generic Electronic Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8406 Power Distribution Fuse 21 Fuse 21 - protects the following circuits: ^ Digital Transmission Range Sensor ^ Junction Box Fuse/Relay Panel Fuse 20 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8407 Power Distribution Fuse 22 Fuse 22 - protects the following circuits: ^ Air Bag Diagnostic Monitor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8408 Power Distribution Fuse 23 Fuse 23 - protects the following circuits: ^ Trailer Tow Battery Charge Relay ^ 4X4 Center Axle Disconnect Solenoid Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8409 ^ Function Selector Switch ^ Rear Integrated Control Panel ^ Recirculation Vacuum Solenoid ^ Auxiliary A/C Mode Actuator ^ Auxiliary A/C Control Module Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8410 Fuse 24 Fuse 24 - protects the following circuits: ^ Function Selector Switch Power Distribution Fuse 25 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8411 Fuse 25 - protects the following circuits: ^ 4 Wheel Anti-Lock Brake System Module ^ 4 Wheel Anti-Lock Brake System Relay Power Distribution Fuse 26 Fuse 26 - protects the following circuits: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8412 ^ Daytime Running Lamps Module ^ Right Headlamp Power Source Power is Supplied Through Multi-Function Switch Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8413 Fuse 27 Fuse 27 - protects the following circuits: ^ Main Light Switch ^ Fog Lamp Relay Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8414 Fuse 28 Fuse 28 - protects the following circuits: ^ Left Headlamp Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8415 Fuse 29 Fuse 29 - protects the following circuits: ^ Autolamp Module ^ Instrument Cluster ^ Transmission Control Switch Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8416 Fuse 30 Fuse 30 - protects the following circuits: ^ Radio Noise Capacitor ^ Ignition Coil ^ PCM Power Diode ^ Coil On Plugs Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8417 Power Distribution Circuit-to-Fuse Cross Reference 4 Wheel Anti-Lock Brake System Module ........................................................................................... ..................................................................... Fuse 14 Accessory Delay Relay .................................... .......................................................................................................................................................... Fuse 25 Air Bag Diagnostic Monitor .................................................................................................... .................................................................................... Fuse 2 Air Suspension Service Switch ........... .............................................................................................................................................................. ........... Fuse 4 Air Suspension Solid State Compressor Relay .......................................................................................................................................................... Fuse 15 All Lock Relays ...................................................................................................................... ..................................................................................... Fuse 3 All Unlock Relays ............................... .............................................................................................................................................................. ........... Fuse 3 Auxiliary A/C Relay ...................................................................................................... ............................................................................................ Fuse 13 Compact Disc Changer ............ .............................................................................................................................................................. ...................... Fuse 6 Console Auxiliary Power Socket ....................................................................... ........................................................................................................ Fuse 11 Daytime Running Lamps Module ..................................................................................................................................... ........................................... Fuse 9 Drover's Unlock Relay ................................................................. ................................................................................................................................ Fuse 3 Engine Fuse Module (Fuse 1) ......................................................................................................................... ........................................................... Fuse 24 Engine Fuse Module (Fuse 2) ................................... ................................................................................................................................................. Fuse 16 Engine Fuse Module (Fuse 3) ........................................................................................................ .............................................................................. Fuse 6 Engine Fuse Module (Fuse 5) .................. .............................................................................................................................................................. ...... Fuse 6 Flip Window Relay ............................................................................................................ ........................................................................................ Fuse 29 Fog Lamp Relay ........................... .............................................................................................................................................................. .................. Fuse 9 Fuel Pump Relay .................................................................................................. ...................................................................................................... Fuse 19 Headlamp Relay ............. .............................................................................................................................................................. ................................ Fuse 8 Heated Grid Relay .................................................................................. ................................................................................................................... Fuse 27 Horn Relay ......... .............................................................................................................................................................. ............................................ Fuse 5 Hybrid Cooling Fan Relay ........................................................... .............................................................................................................................. Fuse 29 Ignition Switch .................................................................................................................................................. ................................................ Fuse 20 & 21 Instrument Panel (I/P) Auxiliary Power Socket ......................................................................................................................................................... Fuse 10 I/P Blower Relay .................................................................................................................... .................................................................................... Fuse 23 Junction Box Fuse/Relay Panel Battery Feed ............................................................................................................................................................ Fuse 22 Junction Box Fuse/Relay Panel ............................................................................................. ........................................................................... Fuse 25 & 27 Main Light Switch .............................. .............................................................................................................................................................. .... Fuse 7 & 8 Multi-Function Switch ................................................................................................... .............................................................................................. Fuse 8 Park Lamp Relay ...................... .............................................................................................................................................................. ..................... Fuse 7 PCM Power Relay ............................................................................................. ........................................................................................................ Fuse 24 Power Seat Control Switch .................................................................................................................................................. ...................................... Fuse 18 Premium Sound Amplifier ............................................................... ............................................................................................................................ Fuse 6 Radio .......... .............................................................................................................................................................. ................................................... Fuse 6 Rear Integrated Control Panel ............................................. ......................................................................................................................................... Fuse 6 Rear Wiper Down Motor Relay ..................................................................................................................... ............................................................ Fuse 12 Rear Wiper Up Motor Relay ..................................... ................................................................................................................................................. Fuse 12 Shift On The Fly Relay ................................................................................................................... ........................................................................... Fuse 17 Sub-Woofer Power .................................... .............................................................................................................................................................. .... Fuse 6 Trailer Electronic Brake Controller ...................................................................................... ..................................................................................... Fuse 28 Trailer Tow Backup Lamp Relay ..... .............................................................................................................................................................. ............. Fuse 1 Trailer Tow Battery Charge Relay ............................................................................. ................................................................................................ Fuse 16 Trailer Tow Running Lamp Relay ................................................................................................................................................... ............................ Fuse 1 Transfer Case Shift Relay .......................................................................... ................................................................................................................ Fuse 17 Fuse 1 Fuse 1 - protects the following circuits: ^ Trailer Tow Running Lamp Relay ^ Trailer Tow Backup Lamp Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8418 Power Distribution Fuse 2 Fuse 2 - protects the following circuits: ^ Air Bag Diagnostic Monitor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8419 Power Distribution Fuse 3 Fuse 3 - protects the following circuits: ^ All Unlock Relay ^ All Lock Relay ^ Driver's Unlock Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8420 Power Distribution Fuse 4 Fuse 4 - protects the following circuits: ^ Air Suspension Service Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8421 Power Distribution Fuse 5 Fuse 5 - protects the following circuits: ^ Horn Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8422 Power Distribution Fuse 6 Fuse 6 - protects the following circuits: ^ Radio ^ Premium Sound Amplifier ^ Compact Disc Changer ^ Rear Integrated Control Panel Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8423 ^ Engine Fuse Module Fuse 3 ^ Engine Fuse Module Fuse 5 ^ Sub-Woofer Power Power Distribution Fuse 7 Fuse 7 - protects the following circuits: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8424 ^ Main Light Switch ^ Park Lamp Relay Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8425 Power Distribution Fuse 8 Fuse 8 - protects the following circuits: ^ Main Light Switch ^ Headlamp Relay ^ Multi-function Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8426 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8427 Power Distribution Fuse 9 Fuse 9 - protects the following circuits: ^ Daytime Running Lamps Module ^ Fog Lamp Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8428 Power Distribution Fuse 10 Fuse 10 - protects the following circuits: ^ Instrument Panel Auxiliary Power Socket Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8429 Power Distribution Fuse 11 Fuse 11 - protects the following circuits: ^ Console Auxiliary Power Socket Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8430 Power Distribution Fuse 12 Fuse 12 - protects the following circuits: ^ Rear Wiper Up Motor Relay ^ Rear Wiper Down Motor Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8431 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: ^ Auxiliary A/C Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8432 Power Distribution Fuse 14 Fuse 14 - protects the following circuits: ^ 4 Wheel Anti-Lock Brake System Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8433 Power Distribution Fuse 15 Fuse 15 - protects the following circuits: ^ Air Suspension Solid State Compressor Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8434 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: ^ Trailer Tow Battery Charge Relay ^ Engine Fuse Module Fuse 2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8435 Power Distribution Fuse 17 Fuse 17 - protects the following circuits: ^ Shift On The Fly Relay ^ Transfer Case Shift Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8436 Power Distribution Fuse 18 Fuse 18 - protects the following circuits: ^ Power Seat Control Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8437 Power Distribution Fuse 19 Fuse 19 - protects the following circuits: ^ Fuel Pump Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8438 Power Distribution Fuse 20 Fuse 20 - protects the following circuits: ^ Ignition Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8439 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8440 Power Distribution Fuse 21 Fuse 21 - protects the following circuits: ^ Ignition Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8441 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8442 Power Distribution Fuse 22 Fuse 22 - protects the following circuits: ^ Junction Box Fuse/Relay Panel Battery Feed Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8443 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8444 Power Distribution Fuse 23 Fuse 23 - protects the following circuits: ^ Instrument Panel Blower Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8445 Power Distribution Fuse 24 Fuse 24 - protects the following circuits: ^ PCM Power Relay ^ Engine Fuse Module Fuse 1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8446 Power Distribution Fuse 25 Fuse 25 - protects the following circuits: ^ Junction Box Fuse/Relay Panel ^ Accessory Delay Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8447 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8448 Power Distribution Fuse 27 Fuse 27 - protects the following circuits: ^ Junction Box Fuse/Relay Panel ^ Heated Grid Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8449 Power Distribution Fuse 28 Fuse 28 - protects the following circuits: ^ Trailer Electronic Brake Controller Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8450 Power Distribution Fuse 29 Fuse 29 - protects the following circuits: ^ Flip Window Relay ^ Hybrid Cooling Fan Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 8451 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Engine Fuse Module Fuse Block: Locations Engine Fuse Module Engine View The Engine Fuse Module is located near the power distribution box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Engine Fuse Module > Page 8456 Fuse Block: Locations Junction Box/Fuse Relay Panel Junction Box Fuse/Relay Panel (Part 1 Of 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Engine Fuse Module > Page 8457 Instrument Panel View The Junction Box/Fuse Relay Panel is located under left side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8460 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8461 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8462 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8463 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8464 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8465 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8466 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8467 Fuse Block: Connector Views Junction Box/Fuse Panel (C243) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8468 Junction Box/Fuse Panel (C242) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8469 Fuse Block: Electrical Diagrams Circuit-to-Fuse Cross Reference 4 Wheel Anti-Lock Brake System Module ........................................................................................... ..................................................................... Fuse 14 Accessory Delay Relay .................................... .......................................................................................................................................................... Fuse 25 Air Bag Diagnostic Monitor .................................................................................................... .................................................................................... Fuse 2 Air Suspension Service Switch ........... .............................................................................................................................................................. ........... Fuse 4 Air Suspension Solid State Compressor Relay .......................................................................................................................................................... Fuse 15 All Lock Relays ...................................................................................................................... ..................................................................................... Fuse 3 All Unlock Relays ............................... .............................................................................................................................................................. ........... Fuse 3 Auxiliary A/C Relay ...................................................................................................... ............................................................................................ Fuse 13 Compact Disc Changer ............ .............................................................................................................................................................. ...................... Fuse 6 Console Auxiliary Power Socket ....................................................................... ........................................................................................................ Fuse 11 Daytime Running Lamps Module ..................................................................................................................................... ........................................... Fuse 9 Drover's Unlock Relay ................................................................. ................................................................................................................................ Fuse 3 Engine Fuse Module (Fuse 1) ......................................................................................................................... ........................................................... Fuse 24 Engine Fuse Module (Fuse 2) ................................... ................................................................................................................................................. Fuse 16 Engine Fuse Module (Fuse 3) ........................................................................................................ .............................................................................. Fuse 6 Engine Fuse Module (Fuse 5) .................. .............................................................................................................................................................. ...... Fuse 6 Flip Window Relay ............................................................................................................ ........................................................................................ Fuse 29 Fog Lamp Relay ........................... .............................................................................................................................................................. .................. Fuse 9 Fuel Pump Relay .................................................................................................. ...................................................................................................... Fuse 19 Headlamp Relay ............. .............................................................................................................................................................. ................................ Fuse 8 Heated Grid Relay .................................................................................. ................................................................................................................... Fuse 27 Horn Relay ......... .............................................................................................................................................................. ............................................ Fuse 5 Hybrid Cooling Fan Relay ........................................................... .............................................................................................................................. Fuse 29 Ignition Switch .................................................................................................................................................. ................................................ Fuse 20 & 21 Instrument Panel (I/P) Auxiliary Power Socket ......................................................................................................................................................... Fuse 10 I/P Blower Relay .................................................................................................................... .................................................................................... Fuse 23 Junction Box Fuse/Relay Panel Battery Feed ............................................................................................................................................................ Fuse 22 Junction Box Fuse/Relay Panel ............................................................................................. ........................................................................... Fuse 25 & 27 Main Light Switch .............................. .............................................................................................................................................................. .... Fuse 7 & 8 Multi-Function Switch ................................................................................................... .............................................................................................. Fuse 8 Park Lamp Relay ...................... .............................................................................................................................................................. ..................... Fuse 7 PCM Power Relay ............................................................................................. ........................................................................................................ Fuse 24 Power Seat Control Switch .................................................................................................................................................. ...................................... Fuse 18 Premium Sound Amplifier ............................................................... ............................................................................................................................ Fuse 6 Radio .......... .............................................................................................................................................................. ................................................... Fuse 6 Rear Integrated Control Panel ............................................. ......................................................................................................................................... Fuse 6 Rear Wiper Down Motor Relay ..................................................................................................................... ............................................................ Fuse 12 Rear Wiper Up Motor Relay ..................................... ................................................................................................................................................. Fuse 12 Shift On The Fly Relay ................................................................................................................... ........................................................................... Fuse 17 Sub-Woofer Power .................................... .............................................................................................................................................................. .... Fuse 6 Trailer Electronic Brake Controller ...................................................................................... ..................................................................................... Fuse 28 Trailer Tow Backup Lamp Relay ..... .............................................................................................................................................................. ............. Fuse 1 Trailer Tow Battery Charge Relay ............................................................................. ................................................................................................ Fuse 16 Trailer Tow Running Lamp Relay ................................................................................................................................................... ............................ Fuse 1 Transfer Case Shift Relay .......................................................................... ................................................................................................................ Fuse 17 Fuse 1 - Trailer Backup and Running Lamp Relays Fuse 1 - protects the following circuits: ^ Trailer Tow Running Lamp Relay ^ Trailer Tow Backup Lamp Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8470 Power Distribution Fuse 2 - Air Bag Diagnostic Monitor Fuse 2 - protects the following circuits: ^ Air Bag Diagnostic Monitor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8471 Power Distribution Fuse 3 - All Unlock/Lock Relays, Drivers' Unlock Relay Fuse 3 - protects the following circuits: ^ All Unlock Relay ^ All Lock Relay ^ Driver's Unlock Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8472 Power Distribution Fuse 4 - Air Suspension Service Switch Fuse 4 - protects the following circuits: ^ Air Suspension Service Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8473 Power Distribution Fuse 5 - Horn Relay Fuse 5 - protects the following circuits: ^ Horn Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8474 Power Distribution Fuse 6 - Var. Sound Sys. Components, Eng. Fuse Mdl Fuses 3 & 5 Fuse 6 - protects the following circuits: ^ Radio ^ Premium Sound Amplifier ^ Compact Disc Changer ^ Rear Integrated Control Panel Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8475 ^ Engine Fuse Module Fuse 3 ^ Engine Fuse Module Fuse 5 ^ Sub-Woofer Power Power Distribution Fuse 7 - Main Light Switch, Park Lamp Relay Fuse 7 - protects the following circuits: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8476 ^ Main Light Switch ^ Park Lamp Relay Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8477 Power Distribution Fuse 8 - Main Light Switch, Headlamp Relay, Multi-function Sw Fuse 8 - protects the following circuits: ^ Main Light Switch ^ Headlamp Relay ^ Multi-function Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8478 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8479 Power Distribution Fuse 9 - DRL Module, Fog Lamp Relay Fuse 9 - protects the following circuits: ^ Daytime Running Lamps Module ^ Fog Lamp Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8480 Power Distribution Fuse 10 - Instrument Panel Aux. Power Socket Fuse 10 - protects the following circuits: ^ Instrument Panel Auxiliary Power Socket Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8481 Power Distribution Fuse 11 - Console Aux. Power Socket Fuse 11 - protects the following circuits: ^ Console Auxiliary Power Socket Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8482 Power Distribution Fuse 12 - Rear Wiper Up And Down Motor Relays Fuse 12 - protects the following circuits: ^ Rear Wiper Up Motor Relay ^ Rear Wiper Down Motor Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8483 Power Distribution Fuse 13 - Auxiliary A/C Relay Fuse 13 - protects the following circuits: ^ Auxiliary A/C Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8484 Power Distribution Fuse 14 - 4 Wheel Anti-Lock Brake System Module Fuse 14 - protects the following circuits: ^ 4 Wheel Anti-Lock Brake System Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8485 Power Distribution Fuse 15 - Air Suspension Solid State Compressor Relay Fuse 15 - protects the following circuits: ^ Air Suspension Solid State Compressor Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8486 Power Distribution Fuse 16 - Trailer Tow Bttry Charge Relay, Eng Fuse Module Fuse2 Fuse 16 - protects the following circuits: ^ Trailer Tow Battery Charge Relay ^ Engine Fuse Module Fuse 2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8487 Power Distribution Fuse 17 - Shift-On-The-Fly Relay, Tranfer Case Shift Relay Fuse 17 - protects the following circuits: ^ Shift On The Fly Relay ^ Transfer Case Shift Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8488 Power Distribution Fuse 18 - Power Seat Control Switch Fuse 18 - protects the following circuits: ^ Power Seat Control Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8489 Power Distribution Fuse 19 - Fuel Pump Relay Fuse 19 - protects the following circuits: ^ Fuel Pump Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8490 Power Distribution Fuse 20 - Ignition Switch Fuse 20 - protects the following circuits: ^ Ignition Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8491 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8492 Power Distribution Fuse 21 - Ignition Switch Fuse 21 - protects the following circuits: ^ Ignition Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8493 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8494 Power Distribution Fuse 22 - Junction Box Fuse/Relay Panel Battery Feed Fuse 22 - protects the following circuits: ^ Junction Box Fuse/Relay Panel Battery Feed Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8495 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8496 Power Distribution Fuse 23 - Instrument Panel Blower Relay Fuse 23 - protects the following circuits: ^ Instrument Panel Blower Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8497 Power Distribution Fuse 24 - PCM Power Relay, Engine Fuse Module Fuse 1 Fuse 24 - protects the following circuits: ^ PCM Power Relay ^ Engine Fuse Module Fuse 1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8498 Power Distribution Fuse 25 - Junction Box Fuse/Relay Panel, Accessory Delay Relay Fuse 25 - protects the following circuits: ^ Junction Box Fuse/Relay Panel ^ Accessory Delay Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8499 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8500 Power Distribution Fuse 27 - Junction Box Fuse/Relay Panel, Heated Grid Relay Fuse 27 - protects the following circuits: ^ Junction Box Fuse/Relay Panel ^ Heated Grid Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8501 Power Distribution Fuse 28 - Trailer Electronic Brake Controller Fuse 28 - protects the following circuits: ^ Trailer Electronic Brake Controller Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8502 Power Distribution Fuse 29 - Flip Window Relay, Hybrid Cooling Fan Relay Fuse 29 - protects the following circuits: ^ Flip Window Relay ^ Hybrid Cooling Fan Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8503 Power Distribution Circuit-to-Fuse Cross Reference 4 Wheel Air Suspension Module ......................................................................................................... ........................................................................ Fuse 6 4 Wheel Air Suspension ................................. ........................................................................................................................................................... Fuse 20 4 Wheel Anti-Lock Brake System Module ............................................................................. ................................................................................... Fuse 25 4 Wheel Anti-Lock Brake System Relay ................................................................................................................................................... ................ Fuse 25 4X4 Center Axle Disconnect Solenoid .................................................................. .................................................................................................... Fuse 23 Air Bag Diagnostic Monitor .............................................................................................................................................................. ............... Fuse 19 & 22 Autolamp Module .......................................................................................... ..................................................................................................... Fuse 4 & 29 Auxiliary A/C Control Module ................................................................................................................................................. ................................ Fuse 23 Auxiliary A/C Mode Actuator ................................................................. .................................................................................................................. Fuse 23 Auxiliary A/C Relay ................................................................................................................................................... ................................................. Fuse 7 Battery Saver Relay ............................................................... .................................................................................................................................... Fuse 14 Blend Door Actuator ...................................................................................................................................... ............................................................. Fuse 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8504 Brake On/Off Switch ............................................................................................................................ ..................................................................... Fuse 13 Brake Pressure Switch .................................... ........................................................................................................................................................... Fuse 13 Cigar Lighter .......................................................................................................................... ...................................................................................... Fuse 3 Coil On Plugs .................................... .............................................................................................................................................................. ........... Fuse 30 Compass Sensor ....................................................................................................... .................................................................................................... Fuse 6 Console Blower Motor ........ .............................................................................................................................................................. .......................... Fuse 7 Data Link Connector ..................................................................................... ............................................................................................................. Fuse 12 Daytime Running Lamps Module ..................................................................................................................................... ............................. Fuse 5,16 & 26 Digital Transmission Range Sensor ............................................. ....................................................................................................................... Fuse 5 & 21 Electronic Variable Orifice Module ....................................................................................................................... ..................................................... Fuse 5 Flasher Relay .................................................................... ........................................................................................................................................... Fuse 1 Fog Lamp Relay .................................................................................................................................. ....................................................................... Fuse 27 Function Selector Switch ............................... ................................................................................................................................................... Fuse 23 & 24 Generic Electronic Module ..................................................................................................... .................................................................. Fuse 6,18,15 & 20 Headlamp Relay ................................. .............................................................................................................................................................. ............ Fuse 4 Heated Backlight Switch ............................................................................................. ............................................................................................... Fuse 17 Heated Grid Relay ................. .............................................................................................................................................................. ........................ Fuse 6 Heater-A/C Control Assembly ........................................................................ ............................................................................................................. Fuse 5 High Beam Headlamps .......................................................................................................................................... .................................................... Fuse 16 Ignition Coil ....................................................................... ........................................................................................................................................ Fuse 30 Instrument Cluster ............................................................................................................................... ........................................................... Fuse 2,19 & 29 Instrument Cluster (Without Daytime Running Lamps) ............................................................................................................................................ Fuse 16 Instrument Illumination .......................................................................................................... .................................................................................... Fuse 18 Interior Lamp Relay .......................... .............................................................................................................................................................. ........... Fuse 14 Junction Box Fuse/Relay Panel ................................................................................. ................................................................................................ Fuse 21 Junction Box Fuse Relay Panel Fuse 20 ..................................................................................................................................... ............................... Fuse 21 Left Headlamp ....................................................................................... .................................................................................................................... Fuse 28 Left Power/Heated Signal Mirror ................................................................................................................ .............................................................. Fuse 17 Main Light Switch ................................................... ...................................................................................................................................... Fuse 8,18 & 27 Overhead Trip Computer Module ................................................................................................... ...................................................................... Fuse 2 & 6 PCM Power Diode ...................................... .............................................................................................................................................................. . Fuse 30 Park Lamp Relay ................................................................................................................. ........................................................................................ Fuse 4 Passive Anti-Theft System Module . .............................................................................................................................................................. ............ Fuse 15 Power Mirror Switch ................................................................................................. .................................................................................................. Fuse 4 Radio Noise Capacitor .......... .............................................................................................................................................................. ....................... Fuse 30 Radio ............................................................................................................. .............................................................................................................. Fuse 8 Rear Integrated Control Panel ....................................................................................................................................... ............................................. Fuse 23 Rear Wiper Pump Relay .......................................................... .................................................................................................................................. Fuse 11 Recirculation Vacuum Solenoid ........................................................................................................... ..................................................................... Fuse 23 Remote Anti-Theft Personality Module ............ .................................................................................................................................................... Fuse 4 & 8 Right Headlamp ......................................................................................................................... ................................................................................ Fuse 26 Right Power/Heated Signal Mirror ........ .............................................................................................................................................................. ...... Fuse 17 Shift Lock Actuator ......................................................................................................... ............................................................................................ Fuse 6 Speed Control Servo/Amplifier Assembly ............................................................................................................................................. ...................... Fuse 5 Steering Wheel Rotation Sensor ...................................................................... ............................................................................................................ Fuse 6 Trailer Tow Battery Charge Relay ....................................................................................................................................... ...................................... Fuse 23 Transmission Control Switch .......................................................... ........................................................................................................................... Fuse 29 Washer Pump Relay ......................................................................................................................................... .......................................................... Fuse 11 Windshield Wiper Motor ............................................. .............................................................................................................................................. Fuse 11 Wiper High/Low Relay ......................................................................................................................... ..................................................................... Fuse 11 Wiper Run/Park Relay ..................................... .......................................................................................................................................................... Fuse 11 Fuse 1 - Flasher Relay Fuse 1 - protects the following circuits: ^ Flasher Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8505 Power Distribution Fuse 2 - Instrument Cluster, OH Trip Computer Fuse 2 - protects the following circuits: ^ Instrument Cluster ^ Overhead Trip Computer Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8506 Power Distribution Fuse 3 - Cigar Lighter Fuse 3 - protects the following circuits: ^ Cigar Lighter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8507 Power Distribution Fuse 4 - Park & Hdlp Relays, Autolamp & RAP Mdl, Pwr Mirror Sw. Fuse 4 - protects the following circuits: ^ Park Lamp Relay ^ Headlamp Relay ^ Autolamp Module ^ Remote Anti-Theft Personality Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8508 ^ Power Mirror Switch Power Distribution Fuse 5 - TRS, DRL Mdl, Spd Ctrl Servo/Amp Assy, HVAC Ctrl Assy Fuse 5 - protects the following circuits: ^ Digital Transmission Range Sensor ^ Daytime Running Lamps Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8509 ^ Speed Control Servo/Amplifier Assembly ^ Heater-A/C Control Assembly ^ Blend Door Actuator ^ Electronic Variable Orifice Module Power Distribution Fuse 6 - Shift Lock, GEM, Air Susp. Mdl, OH Trip Cmptr, Compass Fuse 6 - protects the following circuits: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8510 ^ Shift Lock Actuator ^ Generic Electronic Module ^ 4 Wheel Air Suspension Module ^ Compass Sensor ^ Steering Wheel Rotation Sensor ^ Heated Grid Relay ^ Overhead Trip Computer Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8511 Power Distribution Power Distribution Fuse 7 - Aux. A/C Relay, Blower Motor Fuse 7 - protects the following circuits: ^ Auxiliary A/C Relay ^ Console Blower Motor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8512 Power Distribution Fuse 8 - Radio, Main Light Switch, RAP Module Fuse 8 - protects the following circuits: ^ Radio ^ Main Light Switch ^ Remote Anti-Theft Personality Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8513 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8514 Power Distribution Fuse 11 - Washer Pump, Wiper Run/Park Hi/Lo Relays, Wiper Motor Fuse 11 - protects the following circuits: ^ Washer Pump Relay ^ Wiper Run/Park Relay ^ Wiper High/Low Relay ^ Windshield Wiper Motor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8515 ^ Rear Wiper Pump Relay Power Distribution Fuse 12 - Data Link Connector Fuse 12 - protects the following circuits: ^ Data Link Connector Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8516 Power Distribution Fuse 13 - Brake Pedal Position and Brake Pressure Switches Fuse 13 - protects the following circuits: ^ Brake On/Off Switch ^ Brake Pressure Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8517 Power Distribution Fuse 14 - Battery Saver and Interior Lamp Relays Fuse 14 - protects the following circuits: ^ Battery Saver Relay ^ Interior Lamp Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8518 Power Distribution Fuse 15 - GEM and RAP Modules Fuse 15 - protects the following circuits: ^ Generic Electronic Module ^ Passive Anti-Theft System Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8519 Power Distribution Fuse 16 - Inst. Cluster, DRL Module, High Beam Headlamps Fuse 16 - protects the following circuits: ^ Instrument Cluster (Without Daytime Running Lamps) ^ Daytime Running Lamps Module ^ High Beam Headlamps Power Source Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8520 Power is Supplied Through Multi-Function Switch Power Distribution Fuse 17 - Htd Backlight Sw, Left & Right Pwr/Htd Signal Mirrors Fuse 17 - protects the following circuits: ^ Heated Backlight Switch ^ Left Power/Heated Signal Mirror Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8521 ^ Right Power/Heated Signal Mirror Power Distribution Fuse 18 - Main Light Sw, GEM, Instr. Illumination Fuse 18 - protects the following circuits: ^ Main Light Switch ^ Generic Electronic Module ^ Instrument Illumination Power Source Power is Supplied Through Main Light Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8522 Power Distribution Fuse 19 - Instrument Cluster, Air Bag Diagnostic Monitor Fuse 19 - protects the following circuits: ^ Instrument Cluster ^ Air Bag Diagnostic Monitor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8523 Power Distribution Fuse 20 - 4 Wheel Air Suspension, GEM Fuse 20 - protects the following circuits: ^ 4 Wheel Air Suspension ^ Generic Electronic Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8524 Power Distribution Fuse 21 - Digital Trans. Range Snsr, JB Fuse/Relay Pnl Fuse 20 Fuse 21 - protects the following circuits: ^ Digital Transmission Range Sensor ^ Junction Box Fuse/Relay Panel Fuse 20 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8525 Power Distribution Fuse 22 - Air Bag Diagnostic Monitor Fuse 22 - protects the following circuits: ^ Air Bag Diagnostic Monitor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8526 Power Distribution Fuse 23 - Tow Btty Chg Relay, 4X4 Ctr Axle Disc, Func Selector Fuse 23 - protects the following circuits: ^ Trailer Tow Battery Charge Relay ^ 4X4 Center Axle Disconnect Solenoid Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8527 ^ Function Selector Switch ^ Rear Integrated Control Panel ^ Recirculation Vacuum Solenoid ^ Auxiliary A/C Mode Actuator ^ Auxiliary A/C Control Module Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8528 Fuse 24 - Function Selector Switch Fuse 24 - protects the following circuits: ^ Function Selector Switch Power Distribution Fuse 25 - 4WABS Module and 4WABS Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8529 Fuse 25 - protects the following circuits: ^ 4 Wheel Anti-Lock Brake System Module ^ 4 Wheel Anti-Lock Brake System Relay Power Distribution Fuse 26 - DRL Module and Right Headlamp Fuse 26 - protects the following circuits: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8530 ^ Daytime Running Lamps Module ^ Right Headlamp Power Source Power is Supplied Through Multi-Function Switch Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8531 Fuse 27 - Main Light Switch and Fog Lamp Relay Fuse 27 - protects the following circuits: ^ Main Light Switch ^ Fog Lamp Relay Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8532 Fuse 28 - Left Headlamp Fuse 28 - protects the following circuits: ^ Left Headlamp Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8533 Fuse 29 - Autolamp Module, Instrument Cluster, Trans Ctrl Sw Fuse 29 - protects the following circuits: ^ Autolamp Module ^ Instrument Cluster ^ Transmission Control Switch Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8534 Fuse 30 - Radio Noise Cap., Ignition Coil, PCM Pwr Diode... Fuse 30 - protects the following circuits: ^ Radio Noise Capacitor ^ Ignition Coil ^ PCM Power Diode ^ Coil On Plugs Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8535 Power Distribution Circuit-to-Fuse Cross Reference Compact Disc Changer ....................................................................................................................... ......................................................................... Fuse 3 Powertrain Control Module ............................ ............................................................................................................................................................. Fuse 1 Premium Sound Amplifier ........................................................................................................ ................................................................................... Fuse 5 Radio ................................................... .............................................................................................................................................................. .......... Fuse 3 Rear Integrated Control Panel ...................................................................................... ................................................................................................ Fuse 3 Sub-Woofer Power ................. .............................................................................................................................................................. ....................... Fuse 5 Trailer Tow Left Turn Relay ............................................................................. .......................................................................................................... Fuse 2 Trailer Tow Right Turn Relay ................................................................................................................................................... .................................. Fuse 2 Fuse 1 - Powertrain Control Module Fuse 1 - protects the following circuits: ^ Powertrain Control Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8536 Power Distribution Fuse 2 - Trailer Turn Signal Relays Fuse 2 - protects the following circuits: ^ Trailer Tow Left Turn Relay ^ Trailer Tow Right Turn Relay Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8537 Power Distribution Fuse 3 - Radio, Rear Int. Control Panel, CD Changer Fuse 3 - protects the following circuits: ^ Radio ^ Rear Integrated Control Panel ^ Compact Disc Changer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8538 Power Distribution Fuse 5 - Subwoofer, Prem. Sound Amplifier Fuse 5 - protects the following circuits: ^ Sub-Woofer Power ^ Premium Sound Amplifier Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8539 Power Distribution Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8540 Engine Fuse Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8541 Junction Box Fuse/Relay Panel (Part 1 Of 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8542 Junction Box Fuse/Relay Panel (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8543 Power Distribution Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 8544 Primary Battery Fuses Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 In-Line Connector Faces - C119 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8549 In-Line Connector Faces - C120 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8550 In-Line Connector Faces - C148 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8551 In-Line Connector Faces - C149 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8552 Multiple Junction Connector: Diagrams In-Line Connector Faces - C119 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8553 In-Line Connector Faces - C120 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8554 In-Line Connector Faces - C148 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8555 In-Line Connector Faces - C149 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8556 In-Line Connector Faces - C158 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8557 In-Line Connector Faces - C159 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8558 In-Line Connector Faces - C160 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8559 In-Line Connector Faces - C172 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8560 In-Line Connector Faces - C203 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8561 In-Line Connector Faces - C206 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8562 In-Line Connector Faces - C210 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8563 In-Line Connector Faces - C232 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8564 In-Line Connector Faces - C247 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8565 In-Line Connector Faces - C248 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8566 In-Line Connector Faces - C253 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8567 In-Line Connector Faces - C269 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8568 In-Line Connector Faces - C271 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8569 In-Line Connector Faces - C403 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8570 In-Line Connector Faces - C403 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8571 In-Line Connector Faces - C429 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8572 In-Line Connector Faces - C431 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8573 In-Line Connector Faces - C432 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8574 In-Line Connector Faces - C455 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8575 In-Line Connector Faces - C455 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8576 In-Line Connector Faces - C917 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8577 In-Line Connector Faces - C921 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8578 In-Line Connector Faces - C921 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8579 In-Line Connector Faces - C921 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8580 In-Line Connector Faces - C922 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 8581 In-Line Connector Faces - C941 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay Power Distribution Relay: Locations Trailer Tow Backup Lamp Relay Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 8586 Power Distribution Relay Box The Trailer Tow Backup Lamp Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 8587 Power Distribution Relay: Locations Trailer Tow Battery Charge Relay Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 8588 Power Distribution Relay Box The Trailer Tow Battery Charge Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 8589 Power Distribution Relay: Locations Trailer Tow Left Turn Relay Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 8590 Power Distribution Relay Box The Trailer Tow Left Turn Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 8591 Power Distribution Relay: Locations Trailer Tow Right Turn Relay Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 8592 Power Distribution Relay Box The Trailer Tow Right Turn Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 8593 Power Distribution Relay: Locations Trailer Tow Running Lamp Relay Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 8594 Power Distribution Relay Box The Trailer Tow Running Lamp Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay Power Distribution Relay: Locations Trailer Tow Backup Lamp Relay Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 8600 Power Distribution Relay Box The Trailer Tow Backup Lamp Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 8601 Power Distribution Relay: Locations Trailer Tow Battery Charge Relay Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 8602 Power Distribution Relay Box The Trailer Tow Battery Charge Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 8603 Power Distribution Relay: Locations Trailer Tow Left Turn Relay Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 8604 Power Distribution Relay Box The Trailer Tow Left Turn Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 8605 Power Distribution Relay: Locations Trailer Tow Right Turn Relay Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 8606 Power Distribution Relay Box The Trailer Tow Right Turn Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 8607 Power Distribution Relay: Locations Trailer Tow Running Lamp Relay Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Trailer Tow Backup Lamp Relay > Page 8608 Power Distribution Relay Box The Trailer Tow Running Lamp Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Blower/Flasher Relay Block Relay Box: Locations Blower/Flasher Relay Block Instrument Panel View The Blower/Flasher Relay Block is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Blower/Flasher Relay Block > Page 8613 Relay Box: Locations Lock Relays Body View The Lock Relays are located behind right side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Blower/Flasher Relay Block > Page 8614 Relay Box: Locations Regular Production Option Relay Block Instrument Panel View The Regular Production Option Relay Block is located in dash, above passenger air bag. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block Power/Flasher Relay Block Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 8617 Lock Relays Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 8618 Power Distribution Relay Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 8619 RPO Relay Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Blower/Flasher Relay Block Relay Box: Locations Blower/Flasher Relay Block Instrument Panel View The Blower/Flasher Relay Block is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Blower/Flasher Relay Block > Page 8624 Relay Box: Locations Lock Relays Body View The Lock Relays are located behind right side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Blower/Flasher Relay Block > Page 8625 Relay Box: Locations Regular Production Option Relay Block Instrument Panel View The Regular Production Option Relay Block is located in dash, above passenger air bag. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block Power/Flasher Relay Block Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 8628 Lock Relays Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 8629 Power Distribution Relay Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 8630 RPO Relay Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8636 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8637 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8638 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8639 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8640 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8641 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8642 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8643 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8644 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8645 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8646 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8647 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8648 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8649 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8650 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8651 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8652 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8653 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8654 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8655 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8656 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8657 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8658 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8659 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8660 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8661 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8662 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8663 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8664 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8665 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8666 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8667 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8668 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8669 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8670 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8671 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8672 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8673 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8674 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8675 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8676 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8677 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8678 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8679 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8680 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8681 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8682 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8683 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8684 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8685 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8686 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8687 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8688 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8689 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8690 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8691 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8692 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8693 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8694 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8695 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8696 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8697 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8698 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8699 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8700 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8701 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8702 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8703 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8704 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8705 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8706 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8707 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8708 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8709 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8710 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8711 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8712 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8713 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8714 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8715 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8716 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8717 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8718 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8719 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8720 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8721 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8722 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8723 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8724 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8725 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8726 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8727 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8728 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8729 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8730 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8731 Alignment: Technical Service Bulletins Alignment - Toe Setting Procedure Tip Article No. 98-16-9 08/17/98 STEERING - ALIGNMENT - TOE SET PROCEDURE - SERVICE TIP LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250, NAVIGATOR ISSUE It may be difficult to set toe with the jam nut tie rod sleeve while performing an alignment on some vehicles. This may be caused by the toe adjusting sleeve moving when the opposing jam nut is torqued. ACTION Refer to the following Service Procedure to ensure complete and accurate toe set/alignment by preventing the jam nut from backing off during the toe set procedure. SERVICE PROCEDURE When adjusting toe on 1997-98 F-150/F-250, Expedition, or Navigator, follow this procedure on each side of the vehicle when tightening the jam nuts. 1. Set toe to specification. 2. Make sure the inner and outer ball joint sockets are centered perpendicular to their studs. 3. Prevent the adjuster sleeve from rotating by securing it with a tool (pipe wrench or vise grip) against the lower control arm. 4. Torque one (1) jam nut to 90 Nm (66 lb-ft). 5. Paint a line across the adjuster sleeve and the torqued jam nut and another line across the torqued jam nut and tie rod threads. 6. With the wrench still preventing the adjuster sleeve from rotating, torque the other jam nut to 90 Nm (66 lb-ft). 7. Inspect the paint lines to be sure no relative movement of the adjuster sleeve, jam nut, or tie rod occurred. 8. If movement is detected or toe is no longer within specification, loosen both jam nuts, reset toe if necessary, and repeat procedure. 9. Repeat procedure for other side of vehicle. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 303000, 390000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Base Suspension Alignment: Specifications Base Suspension CASTER LH ........................................................................................................................................................ ................................ (+4.8° ± 1.0°) +3.8° to +5.8° RH ......................................................................... ............................................................................................................... (+5.2° ± 1.0°) +4.2° to +6.2° Total/Split ............................................................................................................................................. .......................... (-0.4° split ± 0.7°) -1.1° to +0.3° CAMBER LH ........................................................................................................................................................ ................................... (-0.1— ± 0.7°) -0.8 to +0.6 RH ........................................................................ ................................................................................................................... (-0.1— ± 0.7°) -0.8 to +0.6 Total/Split .................................................................................................................................... .................................... (0.0° split ± 0.7°) -0.7° to +0.7° TOE LH ........................................................................................................................................................ ...................................................................... 0.10° RH ....................................................................... ...................................................................................................................................................... 0.10° Total/Split .......................................................................................................................................................... (+0.20° Toe-in ± 0.25°) -0.05° to +0.45° RIDE HEIGHT Ride Height w/ Base Suspension Measurement - Original Components ........................................................................................................................ 104-134 mm (4.09-5.28 inches) Reset - Original Components ..................................................................................................................................... 109-115 mm (4.29-4.53 inches) Reset - New Components ........................................................................................................................................... 123-129 mm (4.84-5.08 inches) Rear Curb Ride Height Specifications: Without Air Suspension ................................................................................................................................................. 150-205 mm (5.9-8.1 inches) Vehicle Lean Specifications Maximum allowable variance: Front .................................................................................................................................................... ....................................... 16 mm (5/8 inch) Rear ................................................................................. ........................................................................................................... 19 mm (3/4 inch) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Base Suspension > Page 8734 Alignment: Specifications W/ Air Suspension CASTER LH ........................................................................................................................................................ ................................ (+6.8° ± 1.0°) +5.8° to +7.8° RH ......................................................................... ............................................................................................................... (+7.3° ± 1.0°) +6.3° to +8.3° Total/Split ............................................................................................................................................. .......................... (-2.5° split ± 0.7°) -3.2° to -1.8° CAMBER LH ........................................................................................................................................................ .................................. (-0.3° ± 0.7°) -1.0° to +0.4° RH ......................................................................... ................................................................................................................. (-0.3° ± 0.7°) -1.0° to +0.4° Total/Split ............................................................................................................................................. ........................... (0.0° split ± 0.7°) -0.7° to +0.7° TOE LH ........................................................................................................................................................ ...................................................................... 0.05° RH ....................................................................... ...................................................................................................................................................... 0.03° Total/Split .......................................................................................................................................................... (+0.06° Toe-in ± 0.25°) -0.19° to +0.31° RIDE HEIGHT Ride Height w/ Air Suspension - Ignition Off (Kneel Position) Measurement - Original Components ............................................................................................................................ 62-88 mm (2.44-3.46 inches) Reset - Original Components ......................................................................................................................................... 77-83 mm (3.03-3.27 inches) Reset - New Components ............................................................................................................................................... 77-83 mm (3.03-3.27 inches) Rear Curb Ride Height Specifications: With Air Suspension .............................................................................................................................................. 144.8-148.8 mm (5.7-5.85 inches) Vehicle Lean Specifications Maximum allowable variance: Front .................................................................................................................................................... ....................................... 16 mm (5/8 inch) Rear ................................................................................. ........................................................................................................... 19 mm (3/4 inch) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 8735 Alignment: Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 8736 Alignment: Description and Operation DESCRIPTION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 8737 Caster and camber are adjusted by means of eccentric cams on the upper control arm mounting bolts. Toe is adjusted by the use of the front wheel spindle tie rod adjusting sleeve. The three basic alignment angles are camber, caster and toe. Camber and toe affect tire wear and directional stability, caster affects directional stability only. Camber, caster and toe settings change when the vehicle is loaded. The specifications given in this section are static settings with the vehicle unloaded. CAMBER Camber is the inward or outward tilting of the wheels at the top. When the wheels tilt out at the top the camber is positive (+). When the wheels tilt in at the top the camber is negative (-). The amount of camber is measured in degrees from vertical. Steering axis inclination (included angle) is the center line drawn through the ball joints when viewed from the front. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 8738 CASTER Caster is the tilting of the steering axis either forward or backward from vertical. A backward tilt is positive (+) and a forward tilt is negative (-). TOE Toe is a measurement of how much the front of the wheels are turned in or out from the straight-ahead position. When the wheels are turned in, toe is positive (+)(toe in). When the wheels are turned out, toe is negative (-)(toe out). Toe is measured in degrees, from side to side and totaled. Toe should only be checked and adjusted after the camber and caster have been set to the proper specifications. Wheel Track Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 8739 WHEEL TRACK By design the vehicle has a front track that is wider at the front than the rear. Front track is the distance between the two front tires; rear track is the distance between the two rear tires. Dogtracking DOGTRACKING Dogtracking is the condition where the rear axle is not square to the chassis. Heavily crowned roads may give the illusion of dogtracking. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Caster and Camber Alignment: Service and Repair Caster and Camber 1. Loosen the upper suspension arm cam nuts. 2. To increase caster, move the (A) front of the front suspension upper arm outboard and move the (B) rear of the front suspension upper arm inboard. To increase camber, move the (C) front suspension upper arm outboard equally. 3. To decrease caster, move the (A) front of the front suspension upper arm inboard and move the (B) rear of the front suspension upper arm outboard. To decrease camber, move the (C) front suspension upper arm inboard equally. 4. Tighten the upper suspension arm cam nuts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Caster and Camber > Page 8742 Alignment: Service and Repair Toe 1. Start the engine and center the steering wheel. 2. Turn the engine off, and hold the steering wheel in the "straight forward" position by attaching, a rigid link from the steering wheel to the brake pedal. 3. Check the toe settings; follow manufacturer's instructions. 4. Hold the (A) tie rod end while loosening the (B) toe set jam nuts. 5. Rotate the (A) front wheel spindle tie rod adjusting sleeve to desired position. 6. Tighten the toe set jam nuts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Caster and Camber > Page 8743 NOTE: Whenever the toe set jam nuts are loosened for toe adjustment, the nut and tie rod threads must be cleaned and lubricated. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations Steering Control Module: Locations Instrument Panel View The Electronic Variable Orifice Module is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 8749 Electronic Variable Orifice Steering Module (Without Air Suspension) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations Compressor/Pump Relay: Locations Engine View The Air Suspension Compressor Relay is located near the right headlamp. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 8754 Compressor/Pump Relay: Description and Operation A Solid State Relay is used in the air suspension system for compressor control. The relay incorporates a custom power MOSFET and ceramic hybrid circuitry. The relay switches high current loads in response to low power signals and is controlled by the logic of the control module. The compressor relay is energized by the control module to have high current flow from the battery to the compressor motor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Technical Service Bulletin # 01-12-8 Date: 010625 Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Article No. 01-12-8 06/25/01 ^ SUSPENSION - AIR SUSPENSION - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE ^ ELECTRICAL - LAMP - AIR SUSPENSION LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE FORD: 1997-2001 EXPEDITION LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit a check suspension lamp ON with Diagnostic Trouble Codes (DTC's) B2140 or C2140 even after the Air Suspension switch in the upper RH kick panel has been turned on. This may occur at pre-delivery, following suspension service, or after Air Suspension module replacement. This may be caused by the ride height calibration. ACTION Adjust and/or recalibrate ride height as necessary using the NGS (New Generation Star) Tester. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011208A Recalibrate Ride Height 0.2 Hr. For Rear Air Suspension (R.A.S.) 4X2 Vehicles Only 011208B Recalibrate Ride Height 0.5 Hr. For 4 Wheel Air Suspension (4W.A.S.) (Includes Time To Adjust Torsion Bars 4X4 Vehicles Only) DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000, 390000 Service Procedure NOTE DURING PDI (PRE-DELIVERY INSPECTION) IF "CK SUSP" LIGHT IS ON, PRIOR TO SENDING TO SERVICE, VERIFY SWITCH IN UPPER RIGHT KICK PANEL IS ON. THIS SWITCH IS TURNED OFF DURING VEHICLE SHIPMENT TO PREVENT MODULE FROM SEEKING TRIM HEIGHT WHILE SECURED DOWN FOR TRANSPORT. NOTE AN INADVERTENT B2140 OR C2140 MAY RESULT IF A PARAMETER RESET (CLEAR RIDE HEIGHT) IS SELECTED UNDER NGS ACTIVE COMMANDS, THEN CANCELLED OUT. NOTE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 8763 THE AIR SUSPENSION CONTROL MODULE PART NUMBER IS INTERCHANGEABLE BETWEEN THE REAR AIR SUSPENSION (RAS) AND 4-WHEEL AIR SUSPENSION (4WAS) SYSTEMS, BUT ONCE THE MODULE IS INSTALLED, THE VEHICLE WILL THEN DETERMINE WHETHER VEHICLE IS 4X2 (RAS) OR 4X4 (4WAS) BASED ON VEHICLE HARNESS INPUTS. NOTE MODULES ARE PRE-PROGRAMMED TO SEEK 2.66 VOLTS + 1.02 VOLTS FROM REAR HEIGHT SENSOR (RHGSTEN PARAMETER IDENTIFIER OR PID) AT TRIM HEIGHT. HOWEVER, A NEW OR SWAPPED MODULE REQUIRES CALIBRATION PER STEPS BELOW TO CLEAR A 2140 (INITIALIZATION FAILURE) CODE. NOTE PERFORM 4WAS-AIR SUSP/EVO (ELECTRONIC VARIABLE ORIFICE STEERING) SELF TEST AND MAKE NECESSARY REPAIRS FOR ANY OTHER AIR SUSPENSION DTC'S THAT ARE PRESENT BEFORE ADDRESSING B2140/C2140. WARNING WARNING: BEFORE REPLACING ANY AIR SUSPENSION COMPONENTS, HOISTING, JACKING, OR TOWING, DISCONNECT POWER TO THE SYSTEM BY, TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RIGHT KICK PANEL AREA TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. RAS ONLY - CLEAR 2140 NOTE EVEN RAS (4X2) EQUIPPED VEHICLES REQUIRE STORING RIDE HEIGHT AND TOGGLING FRONT TO "ON" TO CLEAR A CK SUSP LIGHT/214O CODE. THIS ALLOWS THE MODULE TO STORE THE VOLTAGE WITH NO FRONT HEIGHT SENSOR PRESENT, AND MUST BE DONE EVEN WITH CONVENTIONAL (STEEL COIL) FRONT SUSPENSION. 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON", press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step # 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional (on-demand) test is in process. As test completes, verify a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off. 4WAS - CLEAR 2140 DTC - Mechanical NOTE OBSERVE AND REPAIR ANY DAMAGED PARTS OR SYSTEM LEAKS, INSPECTING THE AIR LINE UNION LOCATED UNDER THE BRAKE MASTER CYLINDER FIRST. IF BRAKE FLUID HAS DAMAGED THE LINE, REPLACE THEN REROUTE NEW AIR LINE AWAY FROM AN ORIENTATION DIRECTLY UNDER THE MASTER CYLINDER. BRUSH A SOAPY WATER SOLUTION ON REMAINING SYSTEM CONNECTIONS, INCLUDING INLINE AND "T" UNIONS; AIR LINE RUB POINTS; COMPRESSOR FITTINGS; GATE AND FILL SOLENOIDS; AND AIR SHOCKS/SPRINGS. KEEP IN MIND THAT AIR SPRING LEAKS WHERE THE BAG FOLDS OVER ITSELF MAY NOT BE IMMEDIATELY OBVIOUS WITHOUT CYCLING THE SUSPENSION THROUGH DIFFERENT HEIGHTS. IF AIR BUBBLES ARE DETECTED, REPAIR AS NECESSARY THEN RETEST TO ENSURE LEAK-FREE CONNECTIONS BEFORE COMPLETING THE STEPS BELOW. 1. Bring the vehicle to kneel height by turning ignition key off, gear lever in park, doors closed for up to 30 seconds on level ground. Listen for compressor's vent solenoid to release air from lines before proceeding. Venting should occur within approximately one minute of closing all doors Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 8764 with the key in the "off" position. 2. Erase the module's memory: ^ Trigger 4WAS active commands, PARAMETER RESET (Clear Ride Height) WARNING DO NOT RESET REAR HEIGHT AT THIS TIME! ^ Trigger thru warning message, then toggle FRONT CLR from "OFF" to "ON" Press Cancel NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION! 3. You have now cleared the front kneel voltage stored in the module and B2140 will be present on next key-up. 4. Bleed air from front shocks: ^ Mark existing torsion bar setting, then back off the torsion bar adjustment bolt several turns (until approximately 40 mm (1.5") distance from the bolt head to the bottom surface of the torsion bar adjuster is reached) ^ Select AIR SUSP CNTRL from active command menu (NGS will return to this after previous steps) ^ Trigger VENT FRONT, then wait several seconds for air to vent. Press Cancel to exit. 5. Adjust torsion bars per Workshop Manual section 204-01B. NOTE LEAVE THE NGS CONNECTED IN ACTIVE COMMAND MODES (ENTERED IN STEP 4) 50 THE SYSTEM REMAINS IN DIAGNOSTIC MODE AND NOT OPERATIONAL MODE. 6. Finish by performing the following electrical front height reset steps. 4WAS - CLEAR 2140 DTC - Electrical 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON". press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional on-demand test is in process. As test completes, verity a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off and vehicle height settles out as compressor fills air bladders/shocks. NOTE FOR OTHER AIR SUSPENSION CONCERNS, REFER TO THE APPROPRIATE WORKSHOP MANUAL SECTIONS: 204-05A FOR VEHICLE DYNAMIC SUSPENSION - REAR, OR SECTION 204-05B FOR VEHICLE DYNAMIC SUSPENSION - 4 WHEEL. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 98-25-4 > Dec > 98 > Suspension - Warning Lamp ON/DTC's C1770/C1845 Suspension Control Module: All Technical Service Bulletins Suspension - Warning Lamp ON/DTC's C1770/C1845 Article No. 98-25-4 12/21/98 SUSPENSION - CHECK SUSPENSION LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) C1770 AND/OR C1845 STORED IN MEMORY - VEHICLES BUILT THROUGH 10/1/1998 LIGHT TRUCK: 1997-99 EXPEDITION 1998-99 NAVIGATOR ISSUE Some vehicles equipped with air suspension may exhibit an intermittent check suspension lamp on and Diagnostic Trouble Code (DTC) C1770 and/or C1845 illuminated. Vehicles with these codes may not exhibit any ride height concerns. This may be caused by the air suspension control module. ACTION Replace the air suspension control module with a revised air suspension control module and recalibrate ride height. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Connect New Generation Star (NGS) Tester and go to Air Suspension menu to retrieve stored codes. Confirm that you have code C1770 and/or C1845 in memory. If you have any other codes, proceed with appropriate pinpoint tests in the 1998 Expedition/Navigator Workshop Manual, Section 204-OSA (Rear) or 204-05B (4-Wheel). 2. With NGS Tester, run the air suspension On-Demand self test. If you have any codes, proceed with appropriate pinpoint tests in the Workshop Manual, Section 204-OSA or 204-05B. 3. With NGS Tester, select Active Command Modes menu and manually raise and lower vehicle per Ride Height Adjustment procedure, 1998 Workshop Manual, Section 204-OSA or 204-05B. Monitor vehicle height changes. If vehicle does not respond, follow pinpoint tests for pneumatic failures. If vehicle does function properly, continue with Step 4. 4. Replace air suspension control module per the 1998 Workshop Manual, Section 204-OSA or 204-05B. NOTE A NEW OR EXCHANGED AIR SUSPENSION CONTROL MODULE REQUIRES THAT THE RIDE HEIGHT ADJUSTMENT CALIBRATION PROCESS BE PERFORMED; REFER TO FRONT RIDE HEIGHT RESETTING-CLEAR B2140 DTC. PART NUMBER PART NAME F7SZ-5A919-DB Air Suspension Module (1997-98) XL1Z-5A919-AA Air Suspension Module (1999) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982504A Perform Diagnostics, Install 1.2 Hrs. Air Suspension Module, And Perform Ride Height Adjustment Calibration Process DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Technical Service Bulletin # 01-12-8 Date: 010625 Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Article No. 01-12-8 06/25/01 ^ SUSPENSION - AIR SUSPENSION - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE ^ ELECTRICAL - LAMP - AIR SUSPENSION LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE FORD: 1997-2001 EXPEDITION LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit a check suspension lamp ON with Diagnostic Trouble Codes (DTC's) B2140 or C2140 even after the Air Suspension switch in the upper RH kick panel has been turned on. This may occur at pre-delivery, following suspension service, or after Air Suspension module replacement. This may be caused by the ride height calibration. ACTION Adjust and/or recalibrate ride height as necessary using the NGS (New Generation Star) Tester. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011208A Recalibrate Ride Height 0.2 Hr. For Rear Air Suspension (R.A.S.) 4X2 Vehicles Only 011208B Recalibrate Ride Height 0.5 Hr. For 4 Wheel Air Suspension (4W.A.S.) (Includes Time To Adjust Torsion Bars 4X4 Vehicles Only) DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000, 390000 Service Procedure NOTE DURING PDI (PRE-DELIVERY INSPECTION) IF "CK SUSP" LIGHT IS ON, PRIOR TO SENDING TO SERVICE, VERIFY SWITCH IN UPPER RIGHT KICK PANEL IS ON. THIS SWITCH IS TURNED OFF DURING VEHICLE SHIPMENT TO PREVENT MODULE FROM SEEKING TRIM HEIGHT WHILE SECURED DOWN FOR TRANSPORT. NOTE AN INADVERTENT B2140 OR C2140 MAY RESULT IF A PARAMETER RESET (CLEAR RIDE HEIGHT) IS SELECTED UNDER NGS ACTIVE COMMANDS, THEN CANCELLED OUT. NOTE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 8774 THE AIR SUSPENSION CONTROL MODULE PART NUMBER IS INTERCHANGEABLE BETWEEN THE REAR AIR SUSPENSION (RAS) AND 4-WHEEL AIR SUSPENSION (4WAS) SYSTEMS, BUT ONCE THE MODULE IS INSTALLED, THE VEHICLE WILL THEN DETERMINE WHETHER VEHICLE IS 4X2 (RAS) OR 4X4 (4WAS) BASED ON VEHICLE HARNESS INPUTS. NOTE MODULES ARE PRE-PROGRAMMED TO SEEK 2.66 VOLTS + 1.02 VOLTS FROM REAR HEIGHT SENSOR (RHGSTEN PARAMETER IDENTIFIER OR PID) AT TRIM HEIGHT. HOWEVER, A NEW OR SWAPPED MODULE REQUIRES CALIBRATION PER STEPS BELOW TO CLEAR A 2140 (INITIALIZATION FAILURE) CODE. NOTE PERFORM 4WAS-AIR SUSP/EVO (ELECTRONIC VARIABLE ORIFICE STEERING) SELF TEST AND MAKE NECESSARY REPAIRS FOR ANY OTHER AIR SUSPENSION DTC'S THAT ARE PRESENT BEFORE ADDRESSING B2140/C2140. WARNING WARNING: BEFORE REPLACING ANY AIR SUSPENSION COMPONENTS, HOISTING, JACKING, OR TOWING, DISCONNECT POWER TO THE SYSTEM BY, TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RIGHT KICK PANEL AREA TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. RAS ONLY - CLEAR 2140 NOTE EVEN RAS (4X2) EQUIPPED VEHICLES REQUIRE STORING RIDE HEIGHT AND TOGGLING FRONT TO "ON" TO CLEAR A CK SUSP LIGHT/214O CODE. THIS ALLOWS THE MODULE TO STORE THE VOLTAGE WITH NO FRONT HEIGHT SENSOR PRESENT, AND MUST BE DONE EVEN WITH CONVENTIONAL (STEEL COIL) FRONT SUSPENSION. 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON", press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step # 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional (on-demand) test is in process. As test completes, verify a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off. 4WAS - CLEAR 2140 DTC - Mechanical NOTE OBSERVE AND REPAIR ANY DAMAGED PARTS OR SYSTEM LEAKS, INSPECTING THE AIR LINE UNION LOCATED UNDER THE BRAKE MASTER CYLINDER FIRST. IF BRAKE FLUID HAS DAMAGED THE LINE, REPLACE THEN REROUTE NEW AIR LINE AWAY FROM AN ORIENTATION DIRECTLY UNDER THE MASTER CYLINDER. BRUSH A SOAPY WATER SOLUTION ON REMAINING SYSTEM CONNECTIONS, INCLUDING INLINE AND "T" UNIONS; AIR LINE RUB POINTS; COMPRESSOR FITTINGS; GATE AND FILL SOLENOIDS; AND AIR SHOCKS/SPRINGS. KEEP IN MIND THAT AIR SPRING LEAKS WHERE THE BAG FOLDS OVER ITSELF MAY NOT BE IMMEDIATELY OBVIOUS WITHOUT CYCLING THE SUSPENSION THROUGH DIFFERENT HEIGHTS. IF AIR BUBBLES ARE DETECTED, REPAIR AS NECESSARY THEN RETEST TO ENSURE LEAK-FREE CONNECTIONS BEFORE COMPLETING THE STEPS BELOW. 1. Bring the vehicle to kneel height by turning ignition key off, gear lever in park, doors closed for up to 30 seconds on level ground. Listen for compressor's vent solenoid to release air from lines before proceeding. Venting should occur within approximately one minute of closing all doors Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 8775 with the key in the "off" position. 2. Erase the module's memory: ^ Trigger 4WAS active commands, PARAMETER RESET (Clear Ride Height) WARNING DO NOT RESET REAR HEIGHT AT THIS TIME! ^ Trigger thru warning message, then toggle FRONT CLR from "OFF" to "ON" Press Cancel NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION! 3. You have now cleared the front kneel voltage stored in the module and B2140 will be present on next key-up. 4. Bleed air from front shocks: ^ Mark existing torsion bar setting, then back off the torsion bar adjustment bolt several turns (until approximately 40 mm (1.5") distance from the bolt head to the bottom surface of the torsion bar adjuster is reached) ^ Select AIR SUSP CNTRL from active command menu (NGS will return to this after previous steps) ^ Trigger VENT FRONT, then wait several seconds for air to vent. Press Cancel to exit. 5. Adjust torsion bars per Workshop Manual section 204-01B. NOTE LEAVE THE NGS CONNECTED IN ACTIVE COMMAND MODES (ENTERED IN STEP 4) 50 THE SYSTEM REMAINS IN DIAGNOSTIC MODE AND NOT OPERATIONAL MODE. 6. Finish by performing the following electrical front height reset steps. 4WAS - CLEAR 2140 DTC - Electrical 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON". press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional on-demand test is in process. As test completes, verity a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off and vehicle height settles out as compressor fills air bladders/shocks. NOTE FOR OTHER AIR SUSPENSION CONCERNS, REFER TO THE APPROPRIATE WORKSHOP MANUAL SECTIONS: 204-05A FOR VEHICLE DYNAMIC SUSPENSION - REAR, OR SECTION 204-05B FOR VEHICLE DYNAMIC SUSPENSION - 4 WHEEL. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 98-25-4 > Dec > 98 > Suspension - Warning Lamp ON/DTC's C1770/C1845 Suspension Control Module: Customer Interest Suspension - Warning Lamp ON/DTC's C1770/C1845 Article No. 98-25-4 12/21/98 SUSPENSION - CHECK SUSPENSION LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) C1770 AND/OR C1845 STORED IN MEMORY - VEHICLES BUILT THROUGH 10/1/1998 LIGHT TRUCK: 1997-99 EXPEDITION 1998-99 NAVIGATOR ISSUE Some vehicles equipped with air suspension may exhibit an intermittent check suspension lamp on and Diagnostic Trouble Code (DTC) C1770 and/or C1845 illuminated. Vehicles with these codes may not exhibit any ride height concerns. This may be caused by the air suspension control module. ACTION Replace the air suspension control module with a revised air suspension control module and recalibrate ride height. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Connect New Generation Star (NGS) Tester and go to Air Suspension menu to retrieve stored codes. Confirm that you have code C1770 and/or C1845 in memory. If you have any other codes, proceed with appropriate pinpoint tests in the 1998 Expedition/Navigator Workshop Manual, Section 204-OSA (Rear) or 204-05B (4-Wheel). 2. With NGS Tester, run the air suspension On-Demand self test. If you have any codes, proceed with appropriate pinpoint tests in the Workshop Manual, Section 204-OSA or 204-05B. 3. With NGS Tester, select Active Command Modes menu and manually raise and lower vehicle per Ride Height Adjustment procedure, 1998 Workshop Manual, Section 204-OSA or 204-05B. Monitor vehicle height changes. If vehicle does not respond, follow pinpoint tests for pneumatic failures. If vehicle does function properly, continue with Step 4. 4. Replace air suspension control module per the 1998 Workshop Manual, Section 204-OSA or 204-05B. NOTE A NEW OR EXCHANGED AIR SUSPENSION CONTROL MODULE REQUIRES THAT THE RIDE HEIGHT ADJUSTMENT CALIBRATION PROCESS BE PERFORMED; REFER TO FRONT RIDE HEIGHT RESETTING-CLEAR B2140 DTC. PART NUMBER PART NAME F7SZ-5A919-DB Air Suspension Module (1997-98) XL1Z-5A919-AA Air Suspension Module (1999) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982504A Perform Diagnostics, Install 1.2 Hrs. Air Suspension Module, And Perform Ride Height Adjustment Calibration Process DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations > Electronic Level Control (ELC) Module Suspension Control Module: Locations Electronic Level Control (ELC) Module Instrument Panel View The 4 Wheel Air-Suspension Module is located behind the center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations > Electronic Level Control (ELC) Module > Page 8782 Suspension Control Module: Locations Suspension Control Module Instrument Panel View The 4 Wheel Air-Suspension Module is located behind the center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Diagrams > Electronic Level Control (ELC) Module Suspension Control Module: Diagrams Electronic Level Control (ELC) Module 4 Wheel Air Suspension Module (C295) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Diagrams > Electronic Level Control (ELC) Module > Page 8785 4 Wheel Air Suspension Module (C296) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Diagrams > Electronic Level Control (ELC) Module > Page 8786 Suspension Control Module: Diagrams Suspension Control Module 4 Wheel Air Suspension Module (C295) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Diagrams > Electronic Level Control (ELC) Module > Page 8787 4 Wheel Air Suspension Module (C296) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Description and Operation > Four Wheel Air Suspension Suspension Control Module: Description and Operation Four Wheel Air Suspension A microcontroller-based electronic module controls the air compressor motor (through a solid state relay), and all system solenoids. The module also provides power to front and rear height sensors. The module controls vehicle height adjustments by monitoring the two height sensors, vehicle speed, a steering sensor, acceleration input, the door ajar signal, transfer case signals, and the brake switch. The module also conducts all fail-safe and diagnostic strategies and contains self-test and communication software for testing of the vehicle and related components. The control module is mounted in the passenger compartment inside the instrument panel, above the radio and temperature controls. The air suspension system control module monitors and controls the system through a 32-pin two-way connector. The control module is keyed so that it cannot be plugged into an incorrect harness. There are two sides of the harness connection to the module. Each is uniquely colored and keyed to prevent reversing the connections. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Description and Operation > Four Wheel Air Suspension > Page 8790 Suspension Control Module: Description and Operation Rear Air Suspension A microcontroller-based electronic module controls the air compressor motor (through a solid state relay), and all system solenoids. The module also provides power to the rear height sensor. The module controls vehicle height adjustments by monitoring the one height sensor, vehicle speed, a steering sensor, acceleration input, the door ajar signal, transfer case signals, and the brake switch. The module also conducts all fail-safe and diagnostic strategies and contains self-test and communication software for testing of the vehicle and related components. The control module is mounted in the passenger compartment inside the instrument panel, above the radio and temperature controls. The air suspension system control module monitors and controls the system through a 32-pin two-way connector. The control module is keyed so that it cannot be plugged into an incorrect harness. There are two sides of the harness connection to the module. Each is uniquely colored and keyed to prevent reversing the connections. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Service and Repair > Four Wheel Air Suspension Suspension Control Module: Service and Repair Four Wheel Air Suspension REMOVAL 1. Disconnect battery ground cable. 2. Remove the center instrument panel finish panel. 4 3. Disconnect the transfer case rotary control switch electrical connector. 4. Remove the steering column cover trim panel. 5. Remove the headlamp switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Service and Repair > Four Wheel Air Suspension > Page 8793 6. Remove the LH instrument panel finish panel. (1) Remove the screws. (2) Remove the instrument panel finish panel. 7. Remove the instrument cluster panel. (1) Remove the screws. (2) Remove the instrument cluster panel. 8. Remove the control module mounting bracket screws. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Service and Repair > Four Wheel Air Suspension > Page 8794 9. Lift control module and mounting bracket from instrument panel and disconnect the control module electrical connectors. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Service and Repair > Four Wheel Air Suspension > Page 8795 Suspension Control Module: Service and Repair Rear Air Suspension REMOVAL 1. Disconnect battery ground cable. 2. Remove the center instrument panel finish panel. 3. Remove the steering column cover trim panel. 4. Remove the headlamp switch. 5. Remove the LH instrument panel finish panel. (1) Remove the screws. (2) Remove the instrument panel finish panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Service and Repair > Four Wheel Air Suspension > Page 8796 6. Remove the instrument chaster panel. (1) Remove the screws. (2) Remove the instrument cluster panel. 7. Remove the control module mounting bracket screws. 8. Lift the control module and mounting bracket from the instrument panel and disconnect the control module electrical connectors. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations Steering Angle Sensor: Locations Instrument Panel View The Steering Wheel Rotation Sensor is located behind steering wheel in the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 8802 Steering Angle Sensor: Description and Operation The steering sensor is mounted inside the passenger compartment on the steering column. It provides steering rate and position to the control module through two signals: Steering Sensor A and Steering Sensor B. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Front Ride Height Sensor: Locations Front Body View The Front Height Sensor is located behind left running broad. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Front > Page 8808 Ride Height Sensor: Locations Rear Body View The Rear Height Sensor is located at rear floor panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Description and Operation > Four Wheel Air Suspension Ride Height Sensor: Description and Operation Four Wheel Air Suspension Two height sensors are mounted on the vehicle. The sensors send a voltage signal to the control module. The output ranges from approximately 4.75 volts at minimum height (when the vehicle is low or in full jounce), to 0.25 volts at maximum height (when the vehicle is high or in full rebound). The sensors have a useable range of 80 mm (3 in) compared to total suspension travel of 200-250 mm (8-10 in) at the wheel. Therefore, the sensors are mounted to the suspension at a point where full suspension travel at the wheel is relative to 80 mm (3 in) of travel at the height sensor. The front height sensor upper socket is attached to the bracket to the frame at the upper control arm mounting area and the lower height sensor socket is attached to the upper control arm bracket. The rear height sensor is attached between the No. 5 frame crossmember (upper socket) and the panhard rod (lower socket). Replace a sensor as a unit. When the height sensor gets shorter the vehicle is lowered and this will cause the air compressor to turn on and pump compressed air to the system. When the sensor gets longer the vehicle is being raised and this will cause the air to be vented from the system to lower the vehicle to its trim height level. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Description and Operation > Four Wheel Air Suspension > Page 8811 Ride Height Sensor: Description and Operation Rear Air Suspension When the height sensor gets shorter the rear of the vehicle is lowered and this will cause the air compressor to turn on and pump compressed air to the air springs. When the sensor gets longer the rear of the vehicle is being raised and this will cause the air to be vented from the air springs to lower the vehicle back to its trim height level. One height sensor is mounted on the vehicle. The sensor sends a voltage signal to the control module. The output ranges from approximately 4.75 volts at minimum height (when the vehicle is low or in full jounce), to 0.25 volts at maximum height (when the vehicle is high or in full rebound). The sensor has a useable range of 80 mm (3 in) compared to total suspension travel of 200-250 mm (8 to 10 in) at the wheel. Therefore, the sensor is mounted to the suspension at a point where full rear suspension travel at the wheel is relative to 80 mm of travel at the height sensor. The rear height sensor is attached between the No. 5 frame crossmember (upper socket) and the panhard rod (lower socket). Replace the sensor as a unit. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Adjustments > Inflate and Deflate the Air Suspension System Ride Height Sensor: Adjustments Inflate and Deflate the Air Suspension System 1. Turn the ignition to the run position. WARNING: DO NOT REMOVE AN AIR SPRING UNDER ANY CIRCUMSTANCES WHEN THERE IS PRESSURE IN THE AIR SPRING. DO NOT REMOVE ANY COMPONENTS SUPPORTING AN AIR SPRING WITHOUT EITHER EXHAUSTING THE AIR OR PROVIDING SUPPORT FOR THE AIR SPRING TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. 2. Connect NGS tester to vehicle. 3. Select 1997 4.6L/5.4L Expedition 4WAS module. 4. Select "Air Suspension Control Mode" under "Active Command Modes" menu. (1) Select "VENT REAR" to deflate rear air springs. (2) Select "LIFT REAR" to inflate rear air springs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Adjustments > Inflate and Deflate the Air Suspension System > Page 8814 Ride Height Sensor: Adjustments Rear Height Resetting Procedure 1. Turn ignition key on. 2. Connect NGS tester to the vehicle. 3. Select 1997 4.6L/5.4L Expedition-4WAS module. 4. Measure vehicle rear height (driver side) from the bottom of the frame to the rear jounce bumper bolt rear side of head base. 5. By using NGS tester "active command modes", adjust rear height to 146.8 +/- 2 mm by moving rear of the vehicle down "VENT REAR" or moving rear of the vehicle up "LIFT REAR." 6. Monitor on the right side of the NGS screen rear height sensor voltage. 7. Loosen the ball stud nut on rear height sensor bracket on track bar and adjust by moving with height sensor up or down until rear height sensor voltage is 2.61 +/- 0.03 volt. 8. Tighten nut to specifications. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Adjustments > Page 8815 Ride Height Sensor: Service and Repair REMOVAL 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO S O MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Remove the air suspension height sensor. (1) Disconnect electrical connector. (2) Depress the metal retaining tabs and remove the air suspension height sensor from the ball studs. NOTE: The air suspension height sensor has a plastic harness retainer to suspension that must be unclipped prior to removal. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations Steering Angle Sensor: Locations Instrument Panel View The Steering Wheel Rotation Sensor is located behind steering wheel in the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 8819 Steering Angle Sensor: Description and Operation The steering sensor is mounted inside the passenger compartment on the steering column. It provides steering rate and position to the control module through two signals: Steering Sensor A and Steering Sensor B. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications Suspension Mode Switch: Specifications Switch Bracket Mounting Bolt ........................................................................................................................................... 10.2-13.8 Nm (91-123 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications > Page 8823 Suspension Mode Switch: Description and Operation The air suspension switch is located behind the RH kick panel on a mounting bracket. The switch interrupts power to the control module. The air suspension switch supplies a signal to the control module. Without the control module receiving this signal the load leveling system is inoperative and will not react when rear of the vehicle is raised or lowered. If the air suspension is disabled by turning off air suspension switch, a "CHECK SUSP" will appear in the RH corner of the cluster with the ignition in the run position. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications > Page 8824 Suspension Mode Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front door scuff plate. 3. Remove the cowl side trim panel. 4. Disconnect the air suspension switch electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications > Page 8825 5. Remove the air suspension switch bracket mounting bolt. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Specifications Center Link: Specifications TORQUE SPECIFICATIONS Drag Link to Inner Tie Rod End Castellated Nut (2 Req'd) ................................................................................................................................................... 77-103 Nm (56-75 ft. lbs.) Drag Link to Steering Idler Arm and Bracket Castellated Nut ....................................................................................................................................... 77-103 Nm (56-75 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Specifications > Page 8830 Center Link: Service and Repair REMOVAL 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Remove the steering sector shaft arm drag link castellated nuts. (1) Remove the cotter pins. (2) Remove the castellated nuts. 3. Remove the tie rod end from the steering sector shaft arm drag link. Use Remover to separate the steering sector shaft arm drag link from RH and LH tie rod ends. 4. Remove the steering sector shaft arm drag link. ^ Use Pitman Arm Puller to remove the steering sector shaft arm drag link. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Specifications > Page 8831 INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Diagnostic Connector, Steering > Component Information > Locations Diagnostic Connector: Locations Instrument Panel View The Electronic Variable Orifice Diagnostic Connector is located behind right side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Diagnostic Connector, Steering > Component Information > Locations > Page 8835 Electronic Variable Orifice Test Connector Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Specifications Idler Arm: Specifications TORQUE SPECIFICATIONS Idler Arm & Bracket to Frame Bolt (2 Req'd) ............................................................................................................................................. 170-230 Nm (125.5-169 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Specifications > Page 8839 Idler Arm: Service and Repair REMOVAL 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Remove the steering sector shaft arm drag link castellated nut (1) Remove the cotter pin. (2) Remove the castellated nut. 3. Use (A) Pitman Arm Puller to separate the steering sector shaft arm drag link. 4. Remove the steering idler arm and bracket. (1) Remove the bolts. (2) Remove the steering idler arm and bracket. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Specifications > Page 8840 INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Specifications Pitman Arm: Specifications TORQUE SPECIFICATIONS Sector Shaft Arm: To Drag Link Castellated Nut ............................................................................................................................................ 77-103 Nm (57-75 ft. lbs.) To Sector Shaft Nut ..................................................................................................................................................... 234-316 Nm (173-233 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Specifications > Page 8844 Pitman Arm: Service and Repair REMOVAL 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MARY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Remove the skid plate. (1) Remove the bolts. (2) Remove the skid plate. 3. Slide back the plastic cover from the intermediate steering shaft to the steering gear. 4. Remove the intermediate steering shaft bolt and remove the intermediate steering shaft from the steering gear. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Specifications > Page 8845 5. Remove the steering sector shaft arm drag link castellated nut. (1) Remove the cotter pin. (2) Remove the castellated nut. 6. Use Pitman Arm Puller to separate the steering sector shaft arm drag link. 7. Mark a reference point between the steering gear sector shaft and the steering gear sector shaft arm. 8. Remove the steering gear sector shaft arm to the sector shaft nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Specifications > Page 8846 9. Remove the steering gear to frame mounting bolts. 10. Remove the power steering fluid return line. (1) Support the steering gear. (2) Slide back the spring clamp. (3) Disconnect the power steering fluid return line and allow the fluid to drain. 11. Remove the pressure line from the steering gear and remove the steering gear from the vehicle. 12. Secure the steering gear in a vise. Use Pitman Arm Puller to remove the steering gear sector shaft arm. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Specifications > Page 8847 INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Specifications > Page 8848 NOTE: The steering gear sector shaft arm to sector shaft nut must be installed and tightened to specification prior to installation of the steering gear for clearance purposes. Fill the power steering system with fluid and purge air from system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair Power Steering Bleeding: Service and Repair NOTE: If the air is not purged from the power steering system correctly, pump failure could result. This condition can occur on pre-delivery vehicles with evidence of aerated fluid or on vehicles that have had steering component repairs. A whine heard from the power steering pump may be caused by air in the system. The power steering air purge procedure must be performed under the following conditions: ^ Prior to any component repair for which power steering noise complaints are accompanied by evidence of aerated fluid. ^ After replacement of any power steering system component (gear, hose, etc.). 1. Remove the fluid reservoir cap. 2. Tightly insert the stopper of the vacuum pump into the fluid reservoir. 3. Start the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 8853 4. Apply maximum vacuum for a minimum of three minutes at idle. Maintain maximum vacuum with the source. 5. Release the vacuum and remove the vacuum source. 6. Add fluid to the center mark. 7. Reinstall the vacuum source and apply maximum vacuum. 8. Cycle the steering wheel from stop to stop every 30 seconds for approximately five minutes. CAUTION: Do not hold the steering wheel in the far left or right position or damage to power steering may result. 9. Stop the engine, release the vacuum, and remove the vacuum source. 10. Add fluid if necessary. Install the fluid reservoir cap. 11. Start the engine and cycle the steering wheel from stop to stop every 30 seconds for approximately five minutes. CAUTION: Do not hold the steering wheel in the far left or right position or damage to power steering may result. 12. Check for oil leaks at all connections. If the power steering fluid still shows signs of aeration, repeat this procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Mercon V(R) Fluid Usage TSB 07-1-7 01/22/07 MERCON(R) ATF REPLACED BY MERCON(R) V AS A SERVICE FLUID FOR SOME POWER STEERING SYSTEMS FORD: 1996-1997 Thunderbird 1996-2007 Crown Victoria, Mustang, Taurus 1998-2003 Escort 2000-2007 Focus 2002-2005 Thunderbird 2005-2006 Ford GT 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1996-1997 Aerostar 1996-2007 E-Series, Explorer, Ranger 1997-2004 F-53 Motorhome Chassis 1997-2007 Expedition, F-150, F-Super Duty 1998-2003 Windstar 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2007 Escape 2004-2007 Freestar 2005-2007 Escape Hybrid 1996-1997 Cargo 1996-1998 L-Series 1996-1999 F- B-Series 2000-2007 F-650, F-750 2006-2007 Low Cab Forward LINCOLN: 1996-1998 Mark VIII 1996-1999 Continental 1996-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 1996-1997 Cougar 1996-2005 Sable 1996-2007 Grand Marquis 1999-2002 Cougar 2003-2004 Marauder 2005-2007 Montego 2006-2007 Milan 1997-2007 Mountaineer 1998-2002 Villager 2004-2007 Monterey 2005-2007 Mariner Hybrid, Mariner ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid for power steering systems originally requiring MERCON(R). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage > Page 8858 ACTION Beginning immediately all power steering applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining inventory has been depleted. SERVICE PROCEDURE Service power steering Systems requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. CAUTION APPLICATIONS RECOMMENDING TYPE F AUTOMATIC TRANSMISSION AND POWER STEERING FLUID MUST CONTINUE TO USE THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 8859 Power Steering Fluid: Specifications Use Motorcraft MERCON(r) Multi-Purpose Transmission Fluid, XT-2-QDX or equivalent MERCON(r) approved fluid. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Specifications Power Steering Fluid Cooler: Specifications TORQUE SPECIFICATIONS Power Steering Fluid Cooler Bolts ...................................................................................................................................... 8.9-12 Nm (80-107 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Specifications > Page 8863 Power Steering Fluid Cooler: Service and Repair REMOVAL 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. If equipped, remove the skid plate. (1) Remove the bolts. (2) Remove the skid plate. 3. Remove the lower radiator air deflector (1) Remove the screws. (2) Remove the push clips. (3) Remove the lower radiator air deflector. 4. Disconnect the power steering fluid cooler hoses. (1) Compress and slide the clamps back. (2) Disconnect the hoses. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Specifications > Page 8864 5. Remove the power steering fluid cooler. (1) Remove the bolts. (2) Remove the fluid cooler. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Purge the power steering system of air. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Specifications > Mechanical Specifications Power Steering Fluid Reservoir: Mechanical Specifications TORQUE SPECIFICATIONS Reservoir Bracket Bolts to Exhaust Manifold ................................................................................................................................ 68-92 Nm (50-67 ft. lbs.) Upper Reservoir Bracket Bolt .................................................................................................................................................... 9-12 Nm (80-107 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Specifications > Mechanical Specifications > Page 8869 Power Steering Fluid Reservoir: Pressure, Vacuum and Temperature Specifications Air Purge Vacuum ............................................................................................................................... ........................................... 68-85 kPa (20-25 in-Hg) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Specifications > Page 8870 Power Steering Fluid Reservoir: Service and Repair REMOVAL 1. Remove the engine air cleaner assembly. 2. Drain the power steering fluid reservoir. 3. Disconnect the power steering hoses. (1) Compress and move the power steering hose clamps. (2) Disconnect the power steering return hose and the power steering fluid reservoir hoses. 4. Remove the power steering fluid reservoir and bracket. (1) Remove the bolts. (2) Remove the power steering fluid reservoir and bracket. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Specifications > Page 8871 INSTALLATION 1. To install, reverse the removal procedure. NOTE: Purge the power steering system of air. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications TORQUE SPECIFICATIONS Power Steering Hose Fittings .................................................................................................................................................. 17-23 Nm (12.6-17 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications Power Steering Pump: Mechanical Specifications TORQUE SPECIFICATIONS Power Steering Bracket Bolts ................................................................................................................................................. 8-12 Nm (71-107 inch lbs.) Power Steering to Block Bracket Bolts ................................................................................................................................... 35-45 Nm (25.7-33 ft. lbs.) Power Steering Pump Lower Bolt .............................................................................................................................................. 20-30 Nm (15-20 ft. lbs.) Power Steering Pump Upper Bolts ............................................................................................................................................. 20-30 Nm (15-20 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications > Page 8879 Power Steering Pump: Pressure, Vacuum and Temperature Specifications Relief Pressure .................................................................................................................................... ............................................................ 1300-1430 psi Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications > Page 8880 Power Steering Pump: Capacity Specifications Minimum Capacity ............................................................................................................................... .................................................... 1.4 gpm @ 750 psi Flow ................................................................. .................................................................................................................... 3.0 ± 0.2 gpm @ 50 psi & 2500 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 8881 Power Steering Pump: Description and Operation NOTE: Earlier builds have four bolts mounting the power steering pump to the engine block. The fourth lower bolt behind the pulley on earlier builds may be discarded upon removal of the power steering pump. The CIII power steering pump has the following features: ^ It is a belt-driven, vane-type, power steering pump. ^ It is mounted directly to the engine block by three bolts. ^ The power steering pump is replaced as an assembly. ^ The identification tag attached to the power steering pump indicates the model number and bar code. Refer to these when pump replacement is required. ^ The power steering pump uses a quick connect fitting for the power steering pressure hose. ^ The power steering fluid reservoir is mounted on the LH side of the engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 8882 Power Steering Pump: Testing and Inspection 1. Remove the engine air cleaner assembly. 2. Disconnect the power steering pressure hose from the steering gear. Allow fluid to drain into the drain pan. 3. Install the appropriate Power Steering Analyzer fitting into the steering gear. 4. Install the appropriate Power Steering Analyzer fitting into the power steering pressure hose that was removed from the steering gear. 5. Hook up Power Steering Analyzer in series between the two Power Steering Analyzer fittings. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 8883 6. Verify Power Steering Analyzer valve is open. 7. Place the Dial Thermometer in the power steering fluid reservoir. 8. Fill the system. 9. With the engine running, raise the fluid temperature to 50-60° C (122-140° F) by rotating the steering wheel fully left and fully right several times. CAUTION: Do not hold the steering wheel against the stops for an extended period of time. Damage to the pump could occur. 10. Measure the power steering pump output pressure by closing the valve and increasing the engine speed to 1000-1500 rpm. CAUTION: Do not leave the Power Steering Analyzer valve closed for more than 15 seconds. 11. If the pressure recorded is lower than the minimum specified pressure, replace the pump. If the pressure is too high, inspect for a kinked hose and repair as necessary. 12. Increase engine speed to 2500 rpm. If the flow exceeds the maximum free flow specified, replace the power steering pump. 13. Measure the pressure generated at the steering gear by leaving the valve on Power Steering Analyzer open and decreasing engine speed to 1000-1500 rpm. Rotate the steering wheel fully left or fully right and read the pressure. 14. If the pressure is not within specifications, replace the steering gear. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Power Steering Pump: Service and Repair Power Steering Pump REMOVAL 1. Remove the engine air cleaner assembly. 2. Remove the drive belt. 3. Disconnect the power steering pressure hose from the steering gear. 4. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 5. Disconnect the power steering reservoir pump hose from the power steering pump. ^ Drain the power steering fluid reservoir 6. Disconnect the electronic variable orifice (EVO) electrical correctors Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 8886 7. Remove the upper power steering pump bolts. 8. Remove the lower power steering pump bolt and remove the power steering pump. NOTE: Earlier builds have four bolts mounting the power steering pump to the engine block. The fourth lower bolt behind the pulley on earlier builds may be discarded upon removal of the power steering pump. 9. Remove the power steering pressure hose. NOTE: Secure the power steering pump in a vise. (1) Loosen the power steering pressure hose fitting. (2) Remove the power steering pressure hose. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 8887 1. Install the power steering Teflon(R) seal by stretching the (A) Teflon(R) seal over (B) Teflon(R) Seal Replacer Set until it is large enough to slip over the tube nut. 2. Install the power steering pressure hose. NOTE: Secure the power steering pump in a bench vise. (1) Position the power steering pressure hose. (2) Tighten the pressure hose fitting. 3. Position the power steering pump and loosely install the power steering pump bolts. 4. Tighten the upper power steering pump bolts. 5. Tighten the lower power steering pump bolt. NOTE: Earlier builds have four bolts mounting the power steering pump to the engine block. The fourth lower bolt behind the pulley on earlier builds may be discarded upon removal of the power steering pump. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 8888 6. Connect the power steering reservoir pump hose to the power steering pump. 7. Connect the EVO electrical connector. 8. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. 9. Install the power steering pressure hose to the steering gear. 10. Install the drive belt. 11. Install the engine air cleaner assembly. 12. Purge the power steering system of air. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 8889 Power Steering Pump: Service and Repair Power Steering Pump Pulley REMOVAL CAUTION: Replacement of the power steering pump pulley is necessary after being removed and installed two times. 1. Remove the power steering pump. 2. Hold (A) Steering Pump Pulley Remover and rotate the (B) forcing bolt to remove the power steering pump pulley. INSTALLATION 1. Thread the (B) forcing bolt into the power steering pump and turn (A) Steering Pump Pulley Replacer to install the power steering pump pulley. 2. Install the power steering pump. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations Steering Control Module: Locations Instrument Panel View The Electronic Variable Orifice Module is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations > Page 8893 Electronic Variable Orifice Steering Module (Without Air Suspension) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations Steering Control Module: Locations Instrument Panel View The Electronic Variable Orifice Module is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations > Page 8898 Electronic Variable Orifice Steering Module (Without Air Suspension) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations Steering Angle Sensor: Locations Instrument Panel View The Steering Wheel Rotation Sensor is located behind steering wheel in the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 8903 Steering Angle Sensor: Description and Operation The steering sensor is mounted inside the passenger compartment on the steering column. It provides steering rate and position to the control module through two signals: Steering Sensor A and Steering Sensor B. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Locations Steering Angle Sensor: Locations Instrument Panel View The Steering Wheel Rotation Sensor is located behind steering wheel in the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Locations > Page 8907 Steering Angle Sensor: Description and Operation The steering sensor is mounted inside the passenger compartment on the steering column. It provides steering rate and position to the control module through two signals: Steering Sensor A and Steering Sensor B. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming Deactivation Procedure 1. Disconnect positive battery cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Wait one minute. This is the time required for backup power supply in air bag diagnostic monitor to deplete its stored energy. 3. Remove two back cover plugs and remove screw and washer assemblies retaining driver side air bag module to steering wheel. Disconnect horn electrical connector. Disconnect driver air bag sliding contact electrical connector. Remove driver side air bag module from vehicle. WARNING: Place air bag module on bench with trim cover facing up. 4. Connect Rotunda Air Bag Simulator 105-R0011 or equivalent to vehicle harness at top of steering column. 5. Remove passenger side air bag module. Install Rotunda Air Bag Simulator 105-00012 or equivalent on vehicle harness connector in place of passenger side air bag module. 6. Reconnect positive battery cable. Reactivation Procedure 1. Disconnect positive battery cable. WARNING: The air bag simulator must be removed and the air bag reconnected when the system is reactivated. 2. Wait one minute for backup power supply in air bag diagnostic monitor to deplete stored energy. 3. Remove air bag simulator from vehicle harness connector at top of steering column. 4. Reconnect driver side air bag module. 5. Position driver side air bag module on steering wheel and secure with two screw and washer assemblies (8 mm). Tighten screw and washer assemblies to 10-13 Nm (89-115 lb in). Install two back cover plugs. 6. Remove air bag simulator from vehicle harness connector on passenger side. Reconnect and install passenger side air bag module. 7. Reconnect positive battery cable. 8. Prove out system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 8913 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The check list below should be completed following diagnosis or service of any air bag system concern: 1. Are both air bag crash sensors connected and mounted to the vehicle? 2. Is 3-way connector at base of steering column connected? 3. Are the air bags or air bag simulators connected? 4. Is air bag diagnostic monitor connected? 5. Is vehicle battery connected? Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Service and Repair Key Reminder Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key and turn to the RUN position. 2. Press the (A) ignition switch lock cylinder release tab while pulling out the (B) ignition switch lock cylinder. 3. Remove the key in ignition warning switch. 1. Pry clip down. 2. Push key in ignition warning switch off the rear of the ignition switch lock cylinder. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Service and Repair > Page 8917 2. Verify ignition switch lock cylinder operation. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Specifications Steering Column Cover: Specifications TORQUE SPECIFICATIONS Steering Column Shroud Screws .............................................................................................................................................. 0.7-1.1 Nm (7-9 inch lbs.) Upper Instrument Panel Steering Column Cover Bolts ............................................................................................................................................... 2-3 Nm (18-26 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Specifications Steering Column Lock: Specifications TORQUE SPECIFICATIONS Lock Cylinder Housing Screws .................................................................................................................................................. 18-26 Nm (14-19 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Mechanical Specifications Steering Gear: Mechanical Specifications POWER STEERING GEAR OPERATIONAL SPECIFICATIONS Type ..................................................................................................................................................... ............................. Recirculating Ball Torsion Bar Ratio ...................................................................... ...................................................................................................................................................... 14:1 Turns of Steering Wheel (Lock to Lock-Linkage Disconnected) ................................................................................................. ................................................................... 3.4 Worm Bearing Preload ............................................................................................................................................................. 0.9 Nm (8 inch lbs.) Max. Steering Gear Meshload ............................................................................. ...................................................................................... 2.0 Nm (18 inch lbs.) Total Meshload Over Worm Bearing Preload ............................................................................................................................ 0.45-1 Nm (4-9 inch lbs.)(Over Ends) TORQUE SPECIFICATIONS Ball Guide Clamp Bolts .............................................................................................................................................................. 5-7 Nm (45-62 inch lbs.) Intermediate Shaft Pinch Bolt .................................................................................................................................................... 41-54 Nm (30-40 ft. lbs.) Meshload Adjuster Lock Nut ............................................................................................................................................ 26.3-35 Nm (19.3-25.7 ft. lbs.) Power Steering Gear Race Nut ................................................................................................................................................. 75-122 Nm (55-90 ft. lbs.) Sector Shaft Arm Nut ......................................................................................................................................................... 234-316 Nm (173-233 ft. lbs.) Sector Shaft Housing Cover Bolts ............................................................................................................................................. 61-75 Nm (45-55 ft. lbs.) Steering Gear Allen Head Race Lock Nut ......................................................................................................................... 1.7-2.8 Nm (15-24.9 inch lbs.) Steering Gear Bolts .............................................................................................................. ...................................................... 68-92 Nm (50-67 ft. lbs.) Valve Housing Bolts ............................. ..................................................................................................................................... 40-60 Nm (30-44 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Mechanical Specifications > Page 8928 Steering Gear: Pressure, Vacuum and Temperature Specifications POWER STEERING GEAR OPERATIONAL SPECIFICATIONS Relief Pressure .................................................................................................................................... ............................. 8340-8820 kPa (1210-1270 psi) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Mechanical Specifications > Page 8929 Steering Gear: Capacity Specifications Fluid Capacity (Incl. Pump Reservoir) .................................................................................................................................. 0.75 L (1.6 pints) (Approx.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 8930 Steering Gear: Description and Operation Steering Gear - All Except Motorhome The steering gear has the following features: ^ It is a torsion-bar type hydraulic assisted system. ^ It reduces road shock and vibration. ^ It includes a rotary-style hydraulic valve. ^ It uses a dot matrix ID mark on the gear housing between the valve housing and the sector shaft housing cover. It may have an optional identification tag mounted to the valve housing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 8931 Steering Gear: Adjustments 1. Turn the steering wheel from right lock to left lock at least once. NOTE: The engine should not be running. 2. Remove the driver side air bag. 3. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 4. Remove the steering sector shaft arm drag link castellated nut. (1) Remove the cotter pin. (2) Remove the castellated nut. 5. Use Pitman Arm Puller to separate the steering sector shaft arm drag link. 6. Lower and support the front of the vehicle. NOTE: The front wheels should not touch the ground. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 8932 7. Attach an inch pound torque wrench to the (A) bolt and measure the steering gear meshload from center. NOTE: Reset the steering gear meshload only if the measured rotating torque for total on-center load is less than specification. 8. Adjust if out of specification. 9. Remove the fan blade assembly and fan shroud to access the sector shaft locknut. 10. Adjust the sector shaft to proper rotating torque. (1) Hold the sector shaft and loosen the meshload adjuster locknut. (2) Adjust the sector shaft. 11. Verify that the rotating torque is to specification. Reset if necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 8933 12. Tighten the meshload adjuster locknut. (1) Hold the sector shaft. (2) Tighten the locknut. 13. Install the steering sector shaft arm drag link castellated nut and cotter pin. 14. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. 15. Install the fan blade assembly and fan shroud. 16. Install the driver side air bag. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement Steering Gear: Service and Repair Replacement REMOVAL 1. Remove engine air cleaner assembly. 2. Disconnect the power steering pressure hose and the power steering return hose from the steering gear. 3. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 4. If equipped, remove the skid plate. (1) Remove the bolts. (2) Remove the skid plate. 5. Remove the steering sector shaft arm drag link castellated nut. (1) Remove the cotter pin. (2) Remove the nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 8936 6. Use Pitman Arm Puller to separate the steering sector shaft arm drag link. 7. Remove the (A) dust shield from the (B) valve housing. 8. Remove the intermediate shaft pinch bolt. 9. Slide the intermediate shaft off the steering gear input shaft. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 8937 10. Remove the steering gear bolts and the steering gear. 11. Secure the steering gear in a bench vise, and remove the sector shaft arm nut and lockwasher. 12. Use Pitman Arm Puller to remove the steering gear sector shaft arm. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 8938 INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 8939 NOTE: Purge the power steering system of air. Adjust the steering gear meshload. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 8940 Steering Gear: Service and Repair Overhaul Disassembly NOTE: The steering gear input shaft and seals cannot be repaired or replaced separately. Gear replacement may be necessary. 1. Remove the steering gear. 2. Secure the steering gear in a soft jaw vise with the indexing flat pointed down. 3. Rotate the power steering gear input shaft and control from stop to stop and then center the gear. 4. Remove the steering gear sector shaft housing cover bolts. 5. Tap on the lower end of the steering gear sector shaft. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 8941 6. Remove the steering gear sector shaft. 7. Remove the locking nut from the steering gear sector shaft adjustment screw. 8. Hold the (A) steering gear sector shaft and rotate the (B) steering gear sector shaft housing cover counterclockwise and remove the steering gear sector shaft housing cover. 9. Remove the valve housing bolts and the identification tag. 10. Remove the valve housing and piston assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 8942 11. Remove and discard the valve housing gasket. 12. Remove the ball bearings. (1) Remove the steering gear ball return guide clamp bolts. (2) Remove the steering gear ball return guide clamp. (3) Remove the steering gear ball retune. (4) Rotate the piston over a container to collect the 28 ball bearings. 13. Remove the (A) input shaft valve and housing assembly from the (B) piston. 14. Remove and discard the Teflon(R) seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 8943 15. Install the valve housing in Bench Mounted Holding Fixture and loosen the steering gear Allen head race lock nut. 16. Use Adjuster and Locknut Wrench to remove the power steering gear race nut. 17. Remove the (A) power steering gear input shaft and control from the (B) valve housing. 18. Rotate the valve housing with Bench Mounted Holding Fixture. 19. Use Puller to remove the dust seal from the valve housing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 8944 20. Remove the input shaft snap ring from the valve housing. 21. Rotate the valve housing with Bench Mounted Holding Fixture and use Input Shaft Bearing Seal Tool to remove the bearing and steering gear sector shaft housing oil seal. 22. Remove valve housing from Bench Mounted Holding Fixture. 23. Install the steering gear housing in Bench Mounted Holding Fixture and remove the (A) steering gear sector shaft dust seal from the (B) sector shaft seal bore. 24. Remove the spacer. (1) Remove the snap ring. (2) Remove the spacer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 8945 25. Use Puller to remove the sector shaft seal. NOTE: The steering gear sector shaft bearing is not replaceable. Assembly 1. Lubricate the sector shaft seal bore of the steering gear housing. ^ Use Multi-Purpose Grease DOAZ-l9584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A. 2. Use Sector Shaft Seal Replacer to install the sector shaft seal. ^ Lubricate the sector shaft seal, use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A. 3. Install the spacer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 8946 4. Install the snap ring. 5. Use Sector Shaft Seal Replacer to install the steering gear sector shaft dust seal. ^ Lubricate the steering gear sector shaft dust seal; use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A. NOTE: Place the steering gear sector shaft dust seal on Sector Shaft Seal Replacer so the raised lip is toward the tool. 6. Remove steering gear housing from Bench Mounted Holding Fixture. 7. Position the input shaft bearing in the valve housing and use (A) Input Shaft Bearing Seal Tool Set and a (B) press to seat the bearing. 8. Use (B) Input Shaft Bearing Seal Tool and a (C) press to seat the (A) input shaft seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 8947 9. Install the input shaft snap ring. 10. Use Input Shaft Bearing Seal Tool to install the input shaft dust shield. 11. Mount the valve housing in Bench Mounted Holding Fixture. 12. Install the (A) power steering gear input shaft and control into the (B) valve housing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 8948 13. Position the (A) power steering gear race nut into the (B) valve housing. 14. Use Adjuster and Locknut Wrench to tighten the power steering gear race nut. 15. Install the steering gear Allen head race lock nut. 16. Remove the valve housing from Bench Mounted Holding Fixture and position the piston on the worm gear. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 8949 17. Install the (B) steering gear ball return guide on the (A) piston. WARNING: HOLD THE BALL RETURN GUIDES UNTIL THE CAP OR CLIP IS REINSTALLED. FAILURE TO HOLD THE GUIDES WILL RESULT IN A TRAPPED BALL OR BALLS, WHICH COULD CAUSE A VEHICLE ACCIDENT. IF THE BALL GUIDES BECOME UNSEATED AT ANY TIME, REMOVE ALL THE BALLS AND REPEAT THE PROCEDURE. 18. Rotate the (A) piston while holding the (B) steering gear ball return guide and install the 28 ball bearings into the (C) opening in the ball guide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nstall the ball guide clamp. (1) Position the ball guide clamp. (2) Install the ball guide clamp bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 8950 20. Install a new (B) gasket and then lubricate and install the (A) Teflon(R) seal on the valve housing. ^ Use Multi-Purpose Grease DOAZ-1958lAA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A. 21. Install the piston assembly into the gear housing. NOTE: Make sure to align the oil passages in the gear housing. 22. Rotate the teeth so they are on the same plane as the sector shaft. 23. Loosely install the valve housing bolts. (1) If equipped, install the identification tag prior to installing the valve housing bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 8951 24. Lubricate the (A) O-ring on the (B) sector shaft housing cover. ^ Use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A. 25. Rotate the housing clockwise and install the sector shaft into sector shaft housing. 26. Install the sector shaft locknut. NOTE: The sector shaft locknut will be tightened during the steering gear meshload adjustment. 27. Install the sector shaft housing assembly. NOTE: Loosely install the sector shaft housing bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 8952 28. Tighten the sector shaft housing cover bolts. 29. Tighten the valve housing bolts. 30. Install the steering gear. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Recalls for Steering Shaft: > NHTSA03V196000 > May > 03 > Recall 03V196000: Steering Shaft/Yoke Inspection Steering Shaft: Recalls Recall 03V196000: Steering Shaft/Yoke Inspection DEFECT: On certain pickup trucks and sport utility vehicles, the intermediate shaft yoke can separate from the steering gear input shaft. This could result in loss of steering control, potentially resulting in a vehicle crash without warning. REMEDY: Dealers will inspect the steering intermediate shaft yoke to determine if the yoke is fully seated on the steering gear input shaft. If the yoke is fully seated, no service is required. If the yoke is not fully seated and the bolt groove and spline are visible, the intermediate shaft and bolt will be replaced as well as the bolt at the steering column connection. The manufacturer has reported that owner notification began June 2, 2003. Owners may contact Ford at 1-800-392-3673. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Recalls for Steering Shaft: > 03S02 > May > 03 > Recall - Steering Shaft Yoke Defect Technical Service Bulletin # 03S02 Date: 030501 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Recalls for Steering Shaft: > 03S02 > May > 03 > Recall - Steering Shaft Yoke Defect > Page 8965 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PROMPTLY CORRECT Promptly correct all affected vehicles on your FSA VIN Lists. Also correct other affected vehicles identified in OASIS which are brought to your dealership. PLEASE NOTE Due to the nature of this issue affected customers will be notified by mail as soon as possible. DEALER-OWNER CONTACT Immediately contact any of your affected owners whose names are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Owner Letter and schedule a service date. Note: Your FSA VIN List may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states/provinces/countries. Accordingly limit the use of this listing to the follow-up necessary to complete this action. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. OWNER REFUNDS Ford Motor Company is offering a refund for owner-paid repairs covered by this Safety Recall if the repair was performed prior to the date indicated in the reimbursement plan which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or at their option directly through Ford Motor Company at: P.O. Box 1904, Dearborn, MI 48121. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Recalls for Steering Shaft: > 03S02 > May > 03 > Recall - Steering Shaft Yoke Defect > Page 8966 Claiming Information Program Code: 03S02 Misc. Expense: REFUND Misc. Expense: ADMIN Misc. Expense: 0.2 Hr. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels PARTS RETENTION MANDATORY: Return all replaced Steering Shafts (3B676) to Warranty Parts and Return Center, 15090 Commerce Drive North, Dearborn, MI 48120. Follow normal shipping instructions described in the Warranty and Policy Manual. DEALER PRICE For latest prices refer to DOES II or updated price book. EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE 1. Raise the vehicle on a hoist. 2. Position the dust shield upon the steering shaft, away from the steering gear valve housing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Recalls for Steering Shaft: > 03S02 > May > 03 > Recall - Steering Shaft Yoke Defect > Page 8967 3. Inspect the intermediate shaft yoke at the connection to the steering gear input shaft to determine if the yoke it is fully seated. See Figure 1. ^ If the lower section of splines and the bolt groove are both visible on the steering gear input shaft (see Figure 1 top left view), and if the tip of the input shaft is not protruding past the yoke (see Figure 1 bottom left view), the intermediate shaft is not fully inserted and must be replaced. Refer to Section 211-04, Steering Column, of the appropriate workshop manual for replacement procedures. ^ If the yoke is properly installed, the bolt groove and splines on the input shaft will not be visible between the yoke and the steering gear, and the tip of the input shaft will extend above the yoke (see Figure 1 top and bottom right views). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Recalls for Steering Shaft: > 03S02 > May > 03 > Recall - Steering Shaft Yoke Defect > Page 8968 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Recalls for Steering Shaft: > 03S02 > May > 03 > Recall - Steering Shaft Yoke Defect > Page 8969 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > NHTSA03V196000 > May > 03 > Recall 03V196000: Steering Shaft/Yoke Inspection Steering Shaft: All Technical Service Bulletins Recall 03V196000: Steering Shaft/Yoke Inspection DEFECT: On certain pickup trucks and sport utility vehicles, the intermediate shaft yoke can separate from the steering gear input shaft. This could result in loss of steering control, potentially resulting in a vehicle crash without warning. REMEDY: Dealers will inspect the steering intermediate shaft yoke to determine if the yoke is fully seated on the steering gear input shaft. If the yoke is fully seated, no service is required. If the yoke is not fully seated and the bolt groove and spline are visible, the intermediate shaft and bolt will be replaced as well as the bolt at the steering column connection. The manufacturer has reported that owner notification began June 2, 2003. Owners may contact Ford at 1-800-392-3673. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 03S02 > May > 03 > Recall - Steering Shaft Yoke Defect Technical Service Bulletin # 03S02 Date: 030501 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 03S02 > May > 03 > Recall - Steering Shaft Yoke Defect > Page 8979 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PROMPTLY CORRECT Promptly correct all affected vehicles on your FSA VIN Lists. Also correct other affected vehicles identified in OASIS which are brought to your dealership. PLEASE NOTE Due to the nature of this issue affected customers will be notified by mail as soon as possible. DEALER-OWNER CONTACT Immediately contact any of your affected owners whose names are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Owner Letter and schedule a service date. Note: Your FSA VIN List may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states/provinces/countries. Accordingly limit the use of this listing to the follow-up necessary to complete this action. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. OWNER REFUNDS Ford Motor Company is offering a refund for owner-paid repairs covered by this Safety Recall if the repair was performed prior to the date indicated in the reimbursement plan which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or at their option directly through Ford Motor Company at: P.O. Box 1904, Dearborn, MI 48121. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 03S02 > May > 03 > Recall - Steering Shaft Yoke Defect > Page 8980 Claiming Information Program Code: 03S02 Misc. Expense: REFUND Misc. Expense: ADMIN Misc. Expense: 0.2 Hr. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels PARTS RETENTION MANDATORY: Return all replaced Steering Shafts (3B676) to Warranty Parts and Return Center, 15090 Commerce Drive North, Dearborn, MI 48120. Follow normal shipping instructions described in the Warranty and Policy Manual. DEALER PRICE For latest prices refer to DOES II or updated price book. EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE 1. Raise the vehicle on a hoist. 2. Position the dust shield upon the steering shaft, away from the steering gear valve housing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 03S02 > May > 03 > Recall - Steering Shaft Yoke Defect > Page 8981 3. Inspect the intermediate shaft yoke at the connection to the steering gear input shaft to determine if the yoke it is fully seated. See Figure 1. ^ If the lower section of splines and the bolt groove are both visible on the steering gear input shaft (see Figure 1 top left view), and if the tip of the input shaft is not protruding past the yoke (see Figure 1 bottom left view), the intermediate shaft is not fully inserted and must be replaced. Refer to Section 211-04, Steering Column, of the appropriate workshop manual for replacement procedures. ^ If the yoke is properly installed, the bolt groove and splines on the input shaft will not be visible between the yoke and the steering gear, and the tip of the input shaft will extend above the yoke (see Figure 1 top and bottom right views). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 03S02 > May > 03 > Recall - Steering Shaft Yoke Defect > Page 8982 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 03S02 > May > 03 > Recall - Steering Shaft Yoke Defect > Page 8983 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Page 8984 Steering Shaft: Service and Repair REMOVAL 1. Remove the steering column shaft pinch bolt. (1) Remove the steering column shaft pinch bolt. (2) Slide the intermediate shaft off at the steering column. 2. Remove the (A) dust shield from the (B) valve housing. 3. Remove the intermediate shaft pinch bolt. 4. Slide the intermediate shaft off the steering gear input shaft. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Page 8985 5. Remove the intermediate shaft dash panel seal. (1) Remove the dash panel seal. (2) Remove the shaft from the vehicle. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > Recalls: > NHTSA03V196000 > May > 03 > Recall 03V196000: Steering Shaft/Yoke Inspection Steering Shaft Coupler: Recalls Recall 03V196000: Steering Shaft/Yoke Inspection DEFECT: On certain pickup trucks and sport utility vehicles, the intermediate shaft yoke can separate from the steering gear input shaft. This could result in loss of steering control, potentially resulting in a vehicle crash without warning. REMEDY: Dealers will inspect the steering intermediate shaft yoke to determine if the yoke is fully seated on the steering gear input shaft. If the yoke is fully seated, no service is required. If the yoke is not fully seated and the bolt groove and spline are visible, the intermediate shaft and bolt will be replaced as well as the bolt at the steering column connection. The manufacturer has reported that owner notification began June 2, 2003. Owners may contact Ford at 1-800-392-3673. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > Recalls: > 03S02 > May > 03 > Recall - Steering Shaft Yoke Defect Technical Service Bulletin # 03S02 Date: 030501 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > Recalls: > 03S02 > May > 03 > Recall - Steering Shaft Yoke Defect > Page 8998 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PROMPTLY CORRECT Promptly correct all affected vehicles on your FSA VIN Lists. Also correct other affected vehicles identified in OASIS which are brought to your dealership. PLEASE NOTE Due to the nature of this issue affected customers will be notified by mail as soon as possible. DEALER-OWNER CONTACT Immediately contact any of your affected owners whose names are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Owner Letter and schedule a service date. Note: Your FSA VIN List may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states/provinces/countries. Accordingly limit the use of this listing to the follow-up necessary to complete this action. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. OWNER REFUNDS Ford Motor Company is offering a refund for owner-paid repairs covered by this Safety Recall if the repair was performed prior to the date indicated in the reimbursement plan which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or at their option directly through Ford Motor Company at: P.O. Box 1904, Dearborn, MI 48121. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > Recalls: > 03S02 > May > 03 > Recall - Steering Shaft Yoke Defect > Page 8999 Claiming Information Program Code: 03S02 Misc. Expense: REFUND Misc. Expense: ADMIN Misc. Expense: 0.2 Hr. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels PARTS RETENTION MANDATORY: Return all replaced Steering Shafts (3B676) to Warranty Parts and Return Center, 15090 Commerce Drive North, Dearborn, MI 48120. Follow normal shipping instructions described in the Warranty and Policy Manual. DEALER PRICE For latest prices refer to DOES II or updated price book. EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE 1. Raise the vehicle on a hoist. 2. Position the dust shield upon the steering shaft, away from the steering gear valve housing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > Recalls: > 03S02 > May > 03 > Recall - Steering Shaft Yoke Defect > Page 9000 3. Inspect the intermediate shaft yoke at the connection to the steering gear input shaft to determine if the yoke it is fully seated. See Figure 1. ^ If the lower section of splines and the bolt groove are both visible on the steering gear input shaft (see Figure 1 top left view), and if the tip of the input shaft is not protruding past the yoke (see Figure 1 bottom left view), the intermediate shaft is not fully inserted and must be replaced. Refer to Section 211-04, Steering Column, of the appropriate workshop manual for replacement procedures. ^ If the yoke is properly installed, the bolt groove and splines on the input shaft will not be visible between the yoke and the steering gear, and the tip of the input shaft will extend above the yoke (see Figure 1 top and bottom right views). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > Recalls: > 03S02 > May > 03 > Recall - Steering Shaft Yoke Defect > Page 9001 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > Recalls: > 03S02 > May > 03 > Recall - Steering Shaft Yoke Defect > Page 9002 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Shaft Coupler: > 962523 > Dec > 96 > Recalls for Steering Shaft Coupler: > NHTSA03V196000 > May > 03 > Recall 03V196000: Steering Shaft/Yoke Inspection Steering Shaft Coupler: Recalls Recall 03V196000: Steering Shaft/Yoke Inspection DEFECT: On certain pickup trucks and sport utility vehicles, the intermediate shaft yoke can separate from the steering gear input shaft. This could result in loss of steering control, potentially resulting in a vehicle crash without warning. REMEDY: Dealers will inspect the steering intermediate shaft yoke to determine if the yoke is fully seated on the steering gear input shaft. If the yoke is fully seated, no service is required. If the yoke is not fully seated and the bolt groove and spline are visible, the intermediate shaft and bolt will be replaced as well as the bolt at the steering column connection. The manufacturer has reported that owner notification began June 2, 2003. Owners may contact Ford at 1-800-392-3673. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Shaft Coupler: > 962523 > Dec > 96 > Recalls for Steering Shaft Coupler: > 03S02 > May > 03 > Recall - Steering Shaft Yoke Defect Technical Service Bulletin # 03S02 Date: 030501 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Shaft Coupler: > 962523 > Dec > 96 > Recalls for Steering Shaft Coupler: > 03S02 > May > 03 > Recall - Steering Shaft Yoke Defect > Page 9016 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PROMPTLY CORRECT Promptly correct all affected vehicles on your FSA VIN Lists. Also correct other affected vehicles identified in OASIS which are brought to your dealership. PLEASE NOTE Due to the nature of this issue affected customers will be notified by mail as soon as possible. DEALER-OWNER CONTACT Immediately contact any of your affected owners whose names are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Owner Letter and schedule a service date. Note: Your FSA VIN List may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states/provinces/countries. Accordingly limit the use of this listing to the follow-up necessary to complete this action. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. OWNER REFUNDS Ford Motor Company is offering a refund for owner-paid repairs covered by this Safety Recall if the repair was performed prior to the date indicated in the reimbursement plan which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or at their option directly through Ford Motor Company at: P.O. Box 1904, Dearborn, MI 48121. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Shaft Coupler: > 962523 > Dec > 96 > Recalls for Steering Shaft Coupler: > 03S02 > May > 03 > Recall - Steering Shaft Yoke Defect > Page 9017 Claiming Information Program Code: 03S02 Misc. Expense: REFUND Misc. Expense: ADMIN Misc. Expense: 0.2 Hr. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels PARTS RETENTION MANDATORY: Return all replaced Steering Shafts (3B676) to Warranty Parts and Return Center, 15090 Commerce Drive North, Dearborn, MI 48120. Follow normal shipping instructions described in the Warranty and Policy Manual. DEALER PRICE For latest prices refer to DOES II or updated price book. EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE 1. Raise the vehicle on a hoist. 2. Position the dust shield upon the steering shaft, away from the steering gear valve housing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Shaft Coupler: > 962523 > Dec > 96 > Recalls for Steering Shaft Coupler: > 03S02 > May > 03 > Recall - Steering Shaft Yoke Defect > Page 9018 3. Inspect the intermediate shaft yoke at the connection to the steering gear input shaft to determine if the yoke it is fully seated. See Figure 1. ^ If the lower section of splines and the bolt groove are both visible on the steering gear input shaft (see Figure 1 top left view), and if the tip of the input shaft is not protruding past the yoke (see Figure 1 bottom left view), the intermediate shaft is not fully inserted and must be replaced. Refer to Section 211-04, Steering Column, of the appropriate workshop manual for replacement procedures. ^ If the yoke is properly installed, the bolt groove and splines on the input shaft will not be visible between the yoke and the steering gear, and the tip of the input shaft will extend above the yoke (see Figure 1 top and bottom right views). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Shaft Coupler: > 962523 > Dec > 96 > Recalls for Steering Shaft Coupler: > 03S02 > May > 03 > Recall - Steering Shaft Yoke Defect > Page 9019 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Shaft Coupler: > 962523 > Dec > 96 > Recalls for Steering Shaft Coupler: > 03S02 > May > 03 > Recall - Steering Shaft Yoke Defect > Page 9020 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Shaft Coupler: > Page 9021 Hydraulic Control Assembly - Antilock Brakes: Description and Operation OPERATION When the brakes are applied, brake fluid is forced from the brake master cylinder outlet ports to the Hydraulic Control Unit (HCU) inlet ports. The fluid pressure is transmitted through three normally open solenoid valves inside the HCU, through the outlet ports of HCU to the rear brakes. One circuit of the brake master cylinder feeds the front brakes, while the other circuit feeds the rear brakes. If the Electro-Hydraulic Control Unit ( EHCU) senses that a wheel is about to lock, based on wheel speed sensor data, the solenoid valve will pulse closed preventing more fluid from entering that circuit. The HCU then reads the sensor signal from the affected wheel again. If the wheel is still decelerating, the normally closed solenoid valve for that circuit is opened. Any remaining pressure between the normally open valve and the brake is relieved into the HCU accumulator. Once the affected wheel returns to vehicle speed, the HCU returns the solenoid valves to their normal condition allowing fluid flow to the affected brake. Brake Pulsation During the 4WABS operation, the driver may feel a pulsation in the brake pedal, accompanied by a slight up and down movement in the pedal height. In addition, a mechanical noise from the engine compartment may be heard. The pedal effort and pedal feel during normal braking are similar to that of a conventional power brake system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair Steering Wheel: Service and Repair REMOVAL WARNING: ALWAYS WEAR SAFETY GLASSES WHEN SERVICING AN AIR BAG VEHICLE AND WHEN HANDLING AN AIR BAG. CARRY A LIVE AIR BAG WITH THE BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. AN ACCIDENTAL DEPLOYMENT WILL THEN DEPLOY WITH A MINIMAL CHANCE OF INJURY. PLACE A LIVE AIR BAG ON A BENCH OR OTHER SURFACE WITH THE TRIM COVER UP. AFTER DEPLOYMENT, THE AIR BAG SURFACE MAY CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTER HANDLING A DEPLOYED AIR BAG. NEVER PROBE THE CONNECTORS ON THE AIR BAGS. DOING SO MAY RESULT IN AIR BAG DEPLOYMENT WHICH COULD RESULT IN PERSONAL INJURY. AIR BAG MODULES WITH DISCOLORED OR DAMAGED COVERS OR DEPLOYMENT DOORS MUST BE REPLACED, NOT REPAINTED. VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SYSTEM IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WING PIGTAIL FOR DEFORMATION. IF DAMAGED, THE SENSOR SHOULD BE REPLACED WHETHER OR NOT TT3[E AIR BAG IS DEPLOYED. 1. Remove the battery cables. (1) Remove the battery ground cable. (2) Remove the battery to starter relay cable and wait one minute for the backup power supply to be depleted. NOTE: Make sure the front wheels are in the straight-ahead position. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE SERVICING OR REPLACING ANY AIR BAG SYSTEM COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY TO STARTER RELAY CABLE AND WAIT ONE MINUTE. 2. Remove the driver side air bag module. (1) Remove the two screws. (2) Disconnect the air bag sliding contact electrical connector. (3) Disconnect the horn electrical connector. (4) Remove the driver side air bag module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Page 9025 3. Remove the steering wheel bolt. 4. Use (A) 2-Jaw Puller to remove the steering wheel. CAUTION: Removing the steering wheel without using a puller can damage the column bearings. INSTALLATION 1. Install the steering wheel. (1) Position the steering wheel. (2) Install the bolt. 2. Install the driver side air bag module. (1) Connect the air bag sliding contact electrical connector. (2) Connect the horn electrical connector. (3) Position the driver side air bag module. (4) Install the two screws. 3. Connect the battery cables. (1) Connect the battery to starter relay cable. (2) Connect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Steering - Tie Rod End Inspection Procedures Tie Rod End: Technical Service Bulletins Steering - Tie Rod End Inspection Procedures Article No. 03-15-13 08/04/03 STEERING - TIE ROD END INSPECTION PROCEDURE FORD: 1997-2002 EXPEDITION 1997-2003 F-150 2001-2004 ESCAPE LINCOLN: 1998-2002 NAVIGATOR 2002-2003 BLACKWOOD This article supersedes 03-9-9 to update the vehicle models covered. ISSUE This article is to be used as an updated procedure for inspecting tie rod end wear. ACTION This procedure is designed to supplement the Workshop Manual, as it provides a more detailed tie rod end inspection procedure. SERVICE INFORMATION NOTE FOR ESCAPE VEHICLES, THIS TIE ROD END INSPECTION PROCEDURE SHOULD ONLY BE COMPLETED ON THE OUTER TIE RODS. FOR ESCAPE INNER TIE ROD INSPECTION PROCEDURES, REFER TO WORKSHOP MANUAL SECTION 211-00. Step 1 - Free Play: Check the outer tie rod ends by grasping by hand and push up and down. Check the inner tie rod ends, pushing them front to rear. If any free play is observed in a joint, it is worn and should be replaced. Step 2 - Stud Lash - Free Play: While vehicle is on the ground or on a drive-on hoist, have an assistant rotate the steering wheel rapidly back and forth from 10 o'clock to 2 o'clock to 10 o'clock while observing the inner and outer tie rods. If the outer tie rod ends have any vertical movement or the inner tie rod ends have any horizontal movement, the tie rod end with the observed movement should be replaced. Step 3 - Seal Inspection: Raise the vehicle on a hoist and remove the front wheels. The wheels will need to be turned to the right in order to inspect the passenger side inner tie rod end and to the left to inspect the drivers side inner tie rod end. Inspect all four seals for tears, perforations and wear. If there is any indication of wear or perforations on the seal, that tie rod end should be replaced. Step 4 - Stud Corrosion: For Escape Vehicles - If Squeak is noticed during Step 2, disconnect tie rod from knuckle and articulate stud in socket. If squeak is verified, replace part. While pushing down on seal, at stud end, if corrosion present at contact point at base of stud, replace part. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Steering - Tie Rod End Inspection Procedures > Page 9031 For All Other Vehicles Covered In This Article: Using a wrench, rotate the tie rod end so that the front of the seal on the outer tie rod end is expanded (Figure 1). Using a puffy knife or other hard, flat, dull object, lift the bottom of the seal up, exposing the stud (Figure 2). If any water escapes from the seal in the form of bubbles or in a liquid form, that tie rod end should be replaced. Closely examine the stud for signs of corrosion, especially around the interface with the knuckle. A rag might be needed to clean off any grease on the stud that impairs a good visual inspection. If there is any sign of corrosion, that tie rod end should be replaced. Rotate the tie rod end in the opposite direction to expand the inner tie rod seal. Repeat the inspection procedure used on the outer tie rod. Repeat this entire procedure on the other side of the vehicle. If there is sign of corrosion, that tie rod end should be replaced. NOTE IF ANY TIE ROD ENDS ARE REMOVED, INSPECT THE SEAL AND THE STUD AGAIN NOTING ANY DIFFERENCES IN VISUAL PERCEPTIONS FROM WHEN THE PART WAS ON THE VEHICLE. CHECKING THE STUD AFTER REMOVAL HELPS IMPROVE CONSCIOUSNESS OF ISSUES WHEN INSPECTING PARTS ON VEHICLE. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-9 WARRANTY STATUS: INFORMATION ONLY Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Steering - Tie Rod End Inspection Procedures > Page 9032 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Page 9033 Tie Rod End: Specifications Tie Rod Castellated Nut ........................................................................................................................................................... 77-104 Nm (57-77 ft. lbs.) Toe Set Jam Nuts ...................................................................................... ............................................................................... 77-104 Nm (57-77 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner Tie Rod End: Service and Repair Inner REMOVAL 1. Loosen the lug nuts. (1) Remove the center cap with the plastic coated tip of the lug wrench. (2) With the weight of the vehicle on the wheels, loosen the lug nuts. CAUTION: Do not heat to loosen a seized lug nut. Heat can damage the wheel and the wheel bearings. 2. Raise and Support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THES E OPERATIONS. 3. Remove the tire and wheel assembly. (1) Remove the lug nuts. (2) Remove the tire and wheel assembly. 4. Mark a reference point from the tie rod end to the front wheel spindle tie rod adjusting sleeve. 5. Remove the inner tie rod end castellated nut. (1) Remove the cotter pin. (2) Remove the castellated nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner > Page 9036 6. Use the Remover to separate the tie rod end. 7. Remove the tie rod end (1) Loosen the toe set jam nut. (2) Remove the tie rod end. ^ Count and record rotations. INSTALLATION 1. To install, reverse the removal procedure. 2. Inspect and adjust the toe adjustment. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner > Page 9037 Tie Rod End: Service and Repair Outer REMOVAL 1. Loosen the lug nuts. (1) Remove the center cap with the plastic coated tip of the lug wrench (2) With the weight of the vehicle on the wheels, loosen the lug nuts. CAUTION: Do not heat to loosen a seized lug nut. Heat can damage the wheel and the wheel bearings. 2. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 3. Remove the tire and wheel assembly. (1) Remove the lug nuts. (2) Remove the tire and wheel assembly. 4. Mark a reference point from the tie rod end to the front wheel spindle tie rod adjusting sleeve. 5. Remove the outer tie rod castellated nut. (1) Remove the cotter pin. (2) Remove the castellated nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner > Page 9038 6. Use Pitman Arm Puller to separate the tie rod end. 7. Remove the tie rod end. (1) Loosen the toe set jam nut. (2) Remove the tie rod end. ^ Count and record the rotations. INSTALLATION 1. To install, reverse the removal procedure. 2. Inspect and adjust the toe adjustment. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner > Page 9039 Tie Rod End: Service and Repair Replacement REMOVAL 1. Remove the outer tie rod end. 2. Remove the front wheel spindle tie rod adjusting sleeve. (1) Loosen the toe set jam nut. (2) Remove the front wheel spindle tie rod adjusting sleeve. ^ Count and record the rotations. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Ball Joint, Lower Ball Joint: Specifications Ball Joint, Lower Castellated Nut .................................................................................................................................... ................................. 113-153 Nm (83-112 ft. lbs.) Maximum Radial Play .......................................... ........................................................................................................................... 0.794 mm (1/32 inch) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Ball Joint, Lower > Page 9045 Ball Joint: Specifications Ball Joint, Upper Castellated Nut .................................................................................................................................... ..................................... 77-103 Nm (57-77 ft. lbs.) Maximum Radial Play .......................................... ........................................................................................................................... 0.794 mm (1/32 inch) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Ball Joint, Lower Ball Joint: Testing and Inspection Ball Joint, Lower WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 1. Raise the vehicle and (A) place safety stands under the suspension arm axle beneath the spring. 2. Have an assistant grasp the (B) lower and upper edge of the tire and move the wheel in and out. 3. While the wheel is being moved, observe the lower spindle arm and the lower part of the axle jaw. A 0.794 mm (1/32 inch) or greater movement between the lower portion of the suspension arm and the lower spindle arm indicates that the front suspension lower arm ball joint must be replaced. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Road test the vehicle for normal operation. 4. To check the front suspension upper ball joints, grasp the upper edge of the tire and move the wheel in and out. A 0.794 mm (1/32 inch) or greater movement between the upper spindle arm and the upper portion of the suspension arm indicates that the front suspension upper ball joint must be replaced. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Ball Joint, Lower > Page 9048 Ball Joint: Testing and Inspection Ball Joint, Upper WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 1. Raise the vehicle and (A) place safety stands under the suspension arm axle beneath the spring. 2. Have an assistant grasp the (B) lower and upper edge of the tire and move the wheel in and out. 3. While the wheel is being moved, observe the lower spindle arm and the lower part of the axle jaw. A 0.794 mm (1/32 inch) or greater movement between the lower portion of the suspension arm and the lower spindle arm indicates that the front suspension lower arm ball joint must be replaced. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Road test the vehicle for normal operation. 4. To check the front suspension upper ball joints, grasp the upper edge of the tire and move the wheel in and out. A 0.794 mm (1/32 inch) or greater movement between the upper spindle arm and the upper portion of the suspension arm indicates that the front suspension upper ball joint must be replaced. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket Technical Service Bulletin # 96S60 Date: 970201 Recall - Rear Track Arm/Control Arm Bracket SAFETY RECALL 96960 Certain 1997 Model Year Expeditions Built at Michigan Truck Plant - Rear Axle Track Bar Bracket/Lower Control Arm Bracket ^ Dealer Letter ^ Special Recall Parts Announcement ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information - Part 1: Axle Inspection and, if Necessary, Replacement ^ Attachment III ^ Technical Information - Part 2: Track Bar Bracket Inspection/Modification ^ Attachment IV ^ Revised Technical Instructions - March 11, 1997 ^ Attachment V ^ Revised Technical Instructions and Labor Allowances ^ Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9057 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9058 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. Please Note Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,000 per vehicle. Promptly Correct Affected vehicles on the enclosed list. Other eligible vehicles which are brought to your dealership. Dealer-Owner Contact Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Schedule a service date. Regional Contact Advise regional office if: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9059 ^ an owner cannot be contacted. ^ an owner does not make a service date. Claims Submission Enter claims using DWE. See ACESII Manual, Sections 5 and 6. Warranty and Policy Manual See Sections 5 and 6 of the ACESII Manual. Refunds See Section 3-59 of the ACESII Manual. Rental Cars If an inspection reveals that a new axle must be installed, Ford Motor Company will pay for a loaner or rental vehicle, except for fuel, which will be at owner's expense. Enter the word "LOANER" plus the number of days the vehicle was used in the Miscellaneous Expense area. Attachment II - Labor and Parts Information 1997 Model Year Expedition Track Bar Bracket/Lower Control Arm Bracket Labor Allowances NOTE: Only submit one of the above Labor Operations per vehicle. Be sure to select the correct operation. The labor operations above (except Inspection), contain time to re-torque the lug nuts after the 800 km (500 mile) interval as recommended in the vehicle Owner Guide. Parts Requirements Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9060 A small number of "seed stock" parts will be direct shipped to each Ford Division dealer for this recall as follows: 1 part to dealers with 1 to 5 affected vehicles* 3 parts to dealers with 6 to 9 affected vehicles* 5 parts to dealers with 10 or more affected units* *Based on Ford Motor Company Records Shipment of seed stock parts is expected to be completed by February 21, 1997. Order additional parts by calling Renkim (1-800-325-5621). Be prepared to provide the affected VIN number when calling for additional parts. NOTE: If inspection reveals that a new axle assembly is required, call 1-800-325-5621. When calling this number, be prepared to give the following information: NOTE:you will be charged for the axle assembly. ^ Safety Recall 96S60 ^ VIN Number ^ P & A Code ^ Axle Code (See Attachment III for axle codes) ^ Shipping Address ^ Person to whom parts should be sent ^ Telephone Number NOTE: Removed axles must be returned. See instructions below. Axles which are needlessly replaced will be subject to chargeback. Dealer Price For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book Excess Stock Return Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Parts Return You are required to return the removed axle assembly using the shipping container in which the replacement was received. Store the old axle assembly for receipt of the Direct Ship Document that will be on your Overnite Parts register. Clearly mark on the axle assembly Safety Recall 96S60. UPON RECEIPT OF THE DIRECTSHIP DOCUMENT, ship the removed axle assembly, freight prepaid, to: Sterling Axle Plant Attn: Mr. Monzie Edmonds 39000 Mound Road Sterling Heights, Michigan 48301 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9061 Attachment III - Technical Information Part 1: Axle Rear Axle Lower Control Arm Bracket Inspection and/or Track Bar Bracket Modification Affected Vehicles: 1997 Expedition built at the Michigan Truck Plant from March 1, 1996 through October 10,1996 NOTE: This program contains two parts: Part 1: Axle inspection and, if necessary, replacement Part 2: Track bar bracket inspection/modification NOTE: It is most efficient to perform both inspections before proceeding further. Part 1: Axle Inspection and, If Necessary, Replacement 1. On vehicles equipped with air suspension, turn air suspension switch off. Switch is located in the right side kick panel. 2. Raise and support vehicle. 3. Inspect both rear axle tubes for date code stamps. Clean paint or undercoating to locate date code. See Figure 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9062 ^ It date code stamps are present on both rear axle tubes, no service action is required for the rear axle. Go to PART 2. ^ If date code stamps are not on both rear axle tubes, the rear axle must be replaced. Continue on, to order axle. ^ If inspection reveals that the axle must be replaced, check rear axle ID tag for axle ratio code and ring gear diameter, See Figure 2. ^ Cross reference axle ratio code and ring gear diameter in table below to get axle service part number. See Figure 3. ^ Call RENKIM (1-800-325-5621) to order a new axle. When new rear axle is received, proceed to Rear Axle Replacement. Rear Axle Replacement Vehicles Equipped With Rear Air Suspension (See sections for vehicles with rear coil spring suspension) Removal 1. Lower Vehicle 2. Vent air spring air pressure as follows: ^ Turn air suspension switch on. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9063 ^ Turn the ignition to the run position. ^ Connect the NGS tester to the vehicle. ^ Select 1997 4.6L/5.4L Expedition 4WAS module. ^ Select "Air Suspension Control Mode: under "Active Command Modes" menu. ^ Select "VENT REAR" to deflate rear air springs. ^ Turn air suspension switch off. 3. Install memory saver, then disconnect battery negative terminal. 4. Raise and support vehicle. 5. Remove both rear tire and wheel assemblies. 6. Remove driveshaft retaining bolts, then separate driveshaft from companion flange. 7. Wire driveshaft away from the rear axle. 8. Disconnect rear ABS sensor electrical connector, then detach wiring harness from rear axle. 9. On each side of the vehicle, perform the following: ^ Disconnect parking brake cable from parking brake lever. ^ Separate parking brake cable from disc brake adapter. ^ Remove brake caliper retaining bolts, then position brake caliper away from the rear axle. Do not let caliper hang from the brake hose. ^ Remove O-ring from hub, then remove brake rotor from hub. ^ Remove jounce bumper from axle housing. 10. Remove sway bar retainer-to-rear axle mount retaining bolts. Position sway bar away from rear axle. 11. Disconnect load level sensor from rear axle. 12. Position jack stands under rear axle. 13. Lower vehicle enough to release tension on rear axle attaching points (shock absorbers, control arms). 14. Disconnect track bar from rear axle. Position track bar away from rear axle. 15. On each side of the vehicle, perform the following: ^ Remove upper control arm-to-rear axle retaining bolt. Separate control arm from its mounting. ^ Remove lower control arm-to-rear axle retaining bolt. Separate control arm from its mounting. ^ Remove shock absorber-to-rear axle retaining bolt. Separate shock from its mounting. 16. Disconnect axle vent hose from rear axle. 17. Slowly raise the vehicle. Make sure there are not components that will interfere with vehicle separation from the rear axle. 18. Remove rear axle from jack stands. Installation NOTE: New attaching hardware is provided with the replacement axle assembly. Do not use old attaching hardware. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9064 NOTE: Refer to the table to cross-reference circled letters to part description. 1. Position new rear axle on jack stands. 2. Position differential nose on an upward angle using third jack stand. This will allow control arms to clear axle when vehicle is lowered. 3. Lower vehicle over axle. NOTE: Do not tighten retaining nuts at this time. 4. Connect the following components to the rear axle: ^ Air springs ^ Lower control arms (use bolt [A] and nut [C]). ^ Upper control arms (use bolt [A] and nut [B]). ^ Shock absorbers (use bolt [I] and nut [J]). ^ Sway bar retainers (use bolt [E] and nut [D]). ^ Track bar (use bolt [F] and nut [G]). 5. Raise and support vehicle. 6. Position hydraulic jack under rear axle. 7. Raise rear axle until lower control arms are parallel to the ground. NOTE: Tighten both left and right sides of a component before proceeding to the next component. 8. Tighten the following components: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9065 ^ Lower control arm retaining nuts to 128-172 Nm (95-127 lb/ft). ^ Upper control arm retaining nuts to 128-172 Nm (95-127 lb/ft). ^ Shock absorber lower retaining nuts to 88-119 Nm (65-87 lb/ft). ^ Sway bar retainer bolts to 53-72 Nm (39-53 lb/ft). ^ Track bar retaining nut 170-230 Nm (125-169 lb/ft). 9. Connect axle vent hose to the rear axle. 10. Connect the load level sensor to the rear axle. 11. On each side of the vehicle, perform the following: ^ Connect parking brake cable to the parking brake lever. ^ Connect parking brake cable to the disc brake adapter. ^ Install the brake rotor, then the hub O-ring (use O-ring [L]). ^ Position and install the brake caliper. Tighten the retaining bolts to 27 Nm (20 lb/ft). ^ Install jounce bumper onto the rear axle (use screw [H)). Tighten retaining screw to 34-46 Nm (25-33 lb/ft). 12. Route rear ABS sensor wiring harness, then connect rear ABS sensor electrical connector. 13. Align yellow marks on both the driveshaft and companion flange, then install driveshaft retaining bolts (use bolt [K]). Tighten bolts to 88-119 Nm (65-88 lb/ft). WARNING RETIGHTEN AT 800KM (500 MILES) AFTER ANY WHEEL CHANGE OR ANY TIME THE LUG NUTS ARE LOOSENED. WARNING FAILURE TO RETIGHTEN LUG NUTS AT THE MILEAGE SPECIFIED COULD ALLOW WHEELS TO COME OFF WHILE THE VEHICLE IS IN MOTION, POSSIBLY CAUSING LOSS OF VEHICLE CONTROL AND COLLISION. 14. Install both rear tires and wheel assemblies. Tighten wheel nuts in criss-cross pattern to 115-156 Nm (85-115 lb/ft). 15. Lower Vehicle. 16. Turn on air suspension switch. 17. Start and run vehicle. Make sure air suspension system pressurizes the rear air springs. Rear Coil Spring Suspension Vehicles Equipped With Rear Coil Spring Suspension (See previous section for vehicles with rear air suspension) Removal 1. Remove both rear tire and wheel assemblies. 2. Remove driveshaft retaining bolts, then separate driveshaft from companion flange. 3. Wire drive shaft away from the rear axle. 4. Disconnect rear ABS sensor electrical connector, then detach wiring harness from rear axle. 5. On each side of the vehicle, perform the following: ^ Disconnect parking brake cable from parking brake lever. ^ Separate parking brake cable from disc brake adapter. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9066 ^ Remove brake caliper retaining bolts, then position brake caliper away from the rear axle. Do not let caliper hang from the brake hose. ^ Remove O-ring from hub, then remove brake rotor from hub. ^ Remove jounce bumper from axle housing. 6. Remove sway bar retainer-to-rear axle mount retaining bolts. Position sway bar away from rear axle. 7. Position jack stands under rear axle. 8. Lower vehicle enough to release tension on rear axle attaching points (shock absorbers, control arms). 9. Disconnect track bar from rear axle. Position track bar away from rear axle. 10. On each side of the vehicle, perform the following: ^ Remove upper control arm-to-rear axle retaining bolt. Separate control arm from its mounting. ^ Remove lower control arm-to-rear axle retaining bolt. Separate control arm from its mounting. ^ Remove shock absorber-to-rear axle retaining bolt. Separate shock from its mounting. 11. Disconnect axle vent hose from rear axle. 12. Slowly raise the vehicle. Make sure there are no components that will interfere with vehicle separation from the rear axle. 13. Remove both rear coil springs. 14. Remove rear axle from jack stands. Installation NOTE: New attaching hardware is provided with the replacement axle assembly. Do Not use old attaching hardware. NOTE: Refer to the table to cross-reference circle letters to part description. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9067 1. Position new rear axle on jack stands. 2. Position differential nose on an upward angle using third jack stand. This will allow control arms to clear axle when vehicle is lowered. 3. Lower vehicle over axle. NOTE: Do not tighten retaining nuts at this time. 4. Connect the following components to the rear axle: ^ Lower control arms (use bolt [A] and nut [C]). ^ Upper control arms (use bolt [A] and but [B)). 5. Raise and support vehicle. 6. Position hydraulic lack under rear axle. 7. Raise rear axle until lower control arms are parallel to the ground. NOTE: Tighten both left and right sides of a component before proceeding to the next component. 8. Tighten the following components: ^ Lower control arm retaining nuts to 128-172 Nm (95-127 lb/ft). ^ Upper control arm retaining nuts to 128-172 (95-127 lb/ft). 9. Lower the rear axle until axle is hanging freely from hydraulic jack. 10. Install both coil springs. 11. Raise rear axle, then connect the following components to the rear axle: ^ Shock absorbers (use bolt [I] and nut [J]). ^ Sway bar retainers (use bolt [E] and nut [D]). ^ Track bar (use bolt [F] and nut [G]). NOTE: Tighten both left and right sides of a component before proceeding to the next component. 12. Tighten the following components: ^ Shock absorber lower retaining nuts to 88-119 Nm (65-87 lb/ft). ^ Sway bar retainer bolts to 53-72 Nm (39-53 lb/ft). ^ Track bar retaining nut 170-230 Nm (125-169 lb/ft). 13. Connect axle vent hose to the rear axle. 14. On each side of the vehicle, perform the following: ^ Connect parking brake cable to the parking brake lever. ^ Connect parking brake cable to the disc brake adapter. ^ Install the brake rotor, then the hub O-ring (use O-ring [L]). ^ Position and install the brake caliper. Tighten the retaining bolts to 27 Nm (20 lb/ft). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9068 ^ Install jounce bumper onto the rear axle (use screw [H]). Tighten retaining screw to 34-46 Nm (25-33 lb/ft). 15. Route rear ABS sensor wiring harness, then connect rear ABS sensor electrical connector. 16. Align yellow marks on both the driveshaft and companion flange, then install driveshaft retaining bolts (use bolt [K]). Tighten bolts to 88-119 Nm (65-88 lb/ft). WARNING RETIGHTEN AT 800KM (500 MILES) AFTER ANY WHEEL CHANGE OR ANY TIME THE LUG NUTS ARE LOOSENED. WARNING FAILURE TO RETIGHTEN LUG NUTS AT THE MILEAGE SPECIFIED COULD ALLOW WHEELS TO COME OFF WHILE THE VEHICLE IS IN MOTION, POSSIBLY CAUSING LOSS OF VEHICLE CONTROL AND COLLISION. 17. Install both rear tires and wheel assemblies. Tighten wheel nuts in criss-cross pattern to 115-156 Nm (85-115 lb/ft). 18. Lower vehicle. Attachment III - Technical Information - Part 2: Bar Bracket Rear Axle Lower Control Arm Bracket Inspection and/or Track Bar Bracket Modification Affected Vehicles: 1997 Expedition built at the Michigan Truck Plant from March 1, 1996 through October 10, 1996 NOTE: This program contains two parts: Part 1: Axle inspection and, if necessary, replacement Part 2: Track bar bracket inspection/modification Inspection Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9069 1. Inspect for welds on inside of left track bar bracket. See Figure 4. ^ If welds are present, no track bar bracket service action is required for the vehicle. Lower vehicle and turn air suspension switch on, if equipped. Return vehicle to the customer unless axle is to be replaced. ^ If welds are not present, proceed to Track Bar Bracket Modification. In the rare case where the bracket has been separated from the frame, call Renkim at 1-800-325-5621. Track Bar Bracket Modification 1. Lower vehicle. 2. Remove spare tire assembly. 3. On vehicles equipped with air suspension, vent air spring air pressure as follows: ^ Turn air suspension switch on. ^ Turn the ignition to the run position. ^ Connect the NGS tester to the vehicle. ^ Select 1997 4.6L/5.4L Expedition 4WAS module. ^ Select "Air Suspension Control Mode: under "Active Command Modes" menu. ^ Select "VENT REAR" to deflate rear air springs. ^ Turn air suspension switch off. 4. Install memory saver, then disconnect battery negative cable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9070 5. Raise and support vehicle. 6. Remove both rear tire and wheel assemblies. 7. Remove 0-rings from both rear hubs. 8. Remove inspection cover from left side frame rail above the rear axle. 9. On vehicles equipped with coil spring suspension, remove left rear coil spring as follows: ^ Place hydraulic jack under axle housing. ^ Raise jack slightly to release tension on rear axle components. ^ Remove both rear shock absorber lower mounting bolts. ^ Remove both sway bar to sway bar link retaining bolts. Position sway bar away from links. ^ Lower jack enough to release spring tension. ^ Remove left rear spring. 10. On vehicles equipped with air suspension, remove left rear air spring as follows: ^ Disconnect air spring electrical connector. ^ Disconnect air spring air line. ^ Remove air spring upper and lower retaining clips. ^ Compress air spring as necessary to give enough clearance to remove spring. ^ Remove left rear air spring. 11. Use fan to purge gas vapor from under vehicle. 12. Disconnect and plug EVAP canister vapor line. 13. Disconnect EVAP canister electrical connector. 14. Remove canister retaining nuts, then the canister. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9071 15. Check for outside weld of track bar bracket to frame rail. See Figure 5. NOTE: Perform the following step only if the weld in the previous step is missing. If the weld was present in the previous step, go to Step 17. WARNING POSITION A WELD SHIELD OVER THE FUEL, VAPOR AND BRAKE TUBES IN THE AREA TO BE WELDED. COVER THE SHIELD WITH WET RAGS TO PROTECT IT FROM THE HEAT FROM THE WELDING PROCEDURE. CAUTION Do not use oxy-acetylene torch to weld brackets or frame members. Excessive heat may weaken the metal in the frame members and cause permanent damage. CAUTION As a precaution against damage to electrical components, be sure to disconnect the battery cables before using any welding equipment. Also it is imperative to connect the ground clamp as close to the work area as possible. Perform all welding using Rotunda mig wire feed welder 164-R3667 or equivalent using a 75/25 or 80/20 Argon/CO2 gas mix, and welding wire meeting AWS-E-705 specification. It is essential that the repair welds, particularly on load bearing parts or parts contributing to the strength of the assembly, are equivalent to the original in size, type and strength. 16. To place weld on track bar bracket to frame rail, proceed as follows: ^ Partially lower vehicle. ^ Disconnect positive battery cable from the battery. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9072 ^ Partially raise vehicle. ^ Clean area shown in Figure 6. ^ Using the above recommended or equivalent mig welder, place weld in location shown in Figure 6. The wire in the mig welder should be .035 inch in diameter to weld this location. 17. Install reinforcing plates as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9073 ^ Using supplied reinforcing plate mark location in rear flange of track bar bracket for holes to be drilled out. See Figure 7 and 8. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9074 ^ Using 12 mm drill bit, drill holes in rear flange of track bar bracket. See Figure 9. Make sure to drill straight through the track bar bracket. if holes are drilled on an angle, the inside plate will not line up. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9075 ^ Install two reinforcing plates, bolts and nuts on rear flange of track bar bracket: one on outside of bracket and one inside of crossmember. Tighten to 81.4 Nm (60 lb/ft) and spray with Super Seal Anti-Corrosion Compound or equivalent. See Figure 10. ^ Repeat step 17 on front flange of track bar bracket. 18. On vehicles equipped with air suspension, install left rear air spring as follows: ^ Position air spring in its mountings. ^ Install air spring upper and lower retaining clips. ^ Connect air spring electrical connector. ^ Connect air spring air line. 19. On vehicles equipped with coil spring suspension, install left rear coil spring as follows: ^ Install coil spring in its mountings. ^ Raise jack to position rear axle in its installed position. ^ Position sway bar on sway bar links, then install retaining bolts. Tighten to 86-114 Nm (65-85 lb/ft). ^ Position both rear shock absorbers on their mounting brackets, then install both lower retaining bolts. Tighten bolts to 86-114 Nm (65-85 lb/ft). ^ Remove hydraulic jack. 20. Position EVAP canister on left frame rail, then install retaining nuts. 21. Connect EVAP canister electrical connector. 22. Unplug and connect canister vapor line. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9076 23. Install inspection cover on left side frame rail. 24. Install O-rings on both rear hubs. WARNING RETIGHTEN AT 800KM (500 MILES) AFTER ANY WHEEL CHANGE OR ANY TIME THE LUG NUTS ARE LOOSENED. WARNING FAILURE TO RETIGHTEN LUG NUTS AT THE MILEAGE SPECIFIED COULD ALLOW WHEELS TO COME OFF WHILE THE VEHICLE IS IN MOTION, POSSIBLY CAUSING LOSS OF VEHICLE CONTROL AND COLLISION. 25. Install both rear tire and wheel assemblies. Tighten wheel nuts in criss-cross pattern to 115-156 Nm (85-115 lb/ft). 26. Lower vehicle. 27. Install spare tire. 28. Connect battery cable(s), then remove memory saver. 29. On vehicles equipped with air suspension, turn air suspension switch on. Attachment IV - Revised Technical Instructions Announcing revised Technical Instructions for Safety Recall 96560 (Expedition Rear Axle Lower Control Arm/Track Bar Bracket). The following revisions are necessary because a survey of axles inspected by dealers has revealed that most of these axles did not actually need to be replaced. SUPPLEMENTAL TECHNICAL INSTRUCTIONS: 1. Determine the vehicle build date prior to axle inspection. 2. If vehicle build date is August 10, 1996 or later, no axle inspection and/or replacement is required. However, track bar repairs may still be required for the vehicle. Please begin directly at Step # 4 of the original Technical Instructions if build date is August 10, 1996 or later. 3. If vehicle build date is August 9, 1996 or earlier, please proceed with axle inspection as detailed in the original Technical Instructions EXCEPT AS FOLLOWS: a. Remove the axle identification tape (if present) from the right hand axle tube assembly to reveal the date code stamp. b. If you cannot find date code on both axle tube assemblies, call Ford Axle Hot Line at 1 -800-FORD-AXL (1-800-3673-295) before ordering replacement axle assembly to confirm replacement requirements. Please have vehicle VIN and build date available. c. Upon completion of Axle inspection/replacement, proceed to Step # 4 of the original Technical Instructions for Track Bar repair. 4. When attaching the track bar bracket reinforcement kit (Part Number F75Z-5L005-AA), torque the bolts to 68 Nm (50 lb. ft.), NOT 81.4 Nm (60 lb. ft.). 5. Also, when installing the track bar bracket reinforcement kit, the plates should fit flush to the track bar bracket. As required, excess weld material may need to be ground flush to the bracket. If this is required, submit additional time as "Related Damage". Recall/Service Programs Department March 11, 1997 Attachment V - Revised Technical Instr. and Labor Allowances April 7, 1997 Announcing revised Technical Instructions and Labor Allowances for Safety Recall 96S60 (Expedition Rear Axle Lower Control Arm/Track Bar Bracket). 1. REVISED TECHNICAL INSTRUCTIONS: To simplify the inspection process, inspection for welds inside the left track bar bracket is no longer required. Effective immediately, the Track Bar Retaining Kit is to be installed on all affected vehicles. Remember, when installing the Track Bar Retaining Kit, be sure to torque the bolts to 68 Nm (50 lb.ft.) as noted in our 3/11/97 FAX. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9077 NOTE: Vehicles already reported as INSPECTED only do not have to be returned for the Track Bar Bracket Retaining Kit installation. 2. REVISED LABOR ALLOWANCES: The labor allowances on Attachment II Page 1 of the dealer letter dated February, 1997 have been revised as follows (please annotate your copies appropriately): NOTE: Effective the date of this communication, Labor Operation 96S60A is discontinued because the Track Bar Retaining Bracket Kit is to be installed on all vehicles. Install Track Bar Retaining Plates ONLY (no axle replacement required). (Includes inspection of axle for date codes): NOTE: Also, effective with this communication, Labor Operation 96S60D and Labor Operation 96S60E are discontinued because the Track Bar Retaining Kit is to be installed on all vehicles. Install Track Bar Retaining Plates and new axle assembly. (Includes inspection of axle assembly for date codes): NOTE: Only submit one of the above Labor Operations per vehicle. Be sure to select the correct operation. The labor operations above contain time to re-torque the lug nuts after the 800km (500 mile) interval as recommended in the vehicle Owner Guide. Administrative Allowance - 0.1 Hrs. - Misc. Expense Code "Admin" 3. FOR PREVIOUSLY SUBMITTED CLAIMS: Use the ACESII Online Appeal Procedure to claim the additional time against the original paid repair order that used the previously published labor time. Recall/Service Programs Department April, 1997 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9078 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9079 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket Technical Service Bulletin # 96S60 Date: 970201 Recall - Rear Track Arm/Control Arm Bracket SAFETY RECALL 96960 Certain 1997 Model Year Expeditions Built at Michigan Truck Plant - Rear Axle Track Bar Bracket/Lower Control Arm Bracket ^ Dealer Letter ^ Special Recall Parts Announcement ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information - Part 1: Axle Inspection and, if Necessary, Replacement ^ Attachment III ^ Technical Information - Part 2: Track Bar Bracket Inspection/Modification ^ Attachment IV ^ Revised Technical Instructions - March 11, 1997 ^ Attachment V ^ Revised Technical Instructions and Labor Allowances ^ Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9085 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9086 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. Please Note Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,000 per vehicle. Promptly Correct Affected vehicles on the enclosed list. Other eligible vehicles which are brought to your dealership. Dealer-Owner Contact Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Schedule a service date. Regional Contact Advise regional office if: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9087 ^ an owner cannot be contacted. ^ an owner does not make a service date. Claims Submission Enter claims using DWE. See ACESII Manual, Sections 5 and 6. Warranty and Policy Manual See Sections 5 and 6 of the ACESII Manual. Refunds See Section 3-59 of the ACESII Manual. Rental Cars If an inspection reveals that a new axle must be installed, Ford Motor Company will pay for a loaner or rental vehicle, except for fuel, which will be at owner's expense. Enter the word "LOANER" plus the number of days the vehicle was used in the Miscellaneous Expense area. Attachment II - Labor and Parts Information 1997 Model Year Expedition Track Bar Bracket/Lower Control Arm Bracket Labor Allowances NOTE: Only submit one of the above Labor Operations per vehicle. Be sure to select the correct operation. The labor operations above (except Inspection), contain time to re-torque the lug nuts after the 800 km (500 mile) interval as recommended in the vehicle Owner Guide. Parts Requirements Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9088 A small number of "seed stock" parts will be direct shipped to each Ford Division dealer for this recall as follows: 1 part to dealers with 1 to 5 affected vehicles* 3 parts to dealers with 6 to 9 affected vehicles* 5 parts to dealers with 10 or more affected units* *Based on Ford Motor Company Records Shipment of seed stock parts is expected to be completed by February 21, 1997. Order additional parts by calling Renkim (1-800-325-5621). Be prepared to provide the affected VIN number when calling for additional parts. NOTE: If inspection reveals that a new axle assembly is required, call 1-800-325-5621. When calling this number, be prepared to give the following information: NOTE:you will be charged for the axle assembly. ^ Safety Recall 96S60 ^ VIN Number ^ P & A Code ^ Axle Code (See Attachment III for axle codes) ^ Shipping Address ^ Person to whom parts should be sent ^ Telephone Number NOTE: Removed axles must be returned. See instructions below. Axles which are needlessly replaced will be subject to chargeback. Dealer Price For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book Excess Stock Return Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Parts Return You are required to return the removed axle assembly using the shipping container in which the replacement was received. Store the old axle assembly for receipt of the Direct Ship Document that will be on your Overnite Parts register. Clearly mark on the axle assembly Safety Recall 96S60. UPON RECEIPT OF THE DIRECTSHIP DOCUMENT, ship the removed axle assembly, freight prepaid, to: Sterling Axle Plant Attn: Mr. Monzie Edmonds 39000 Mound Road Sterling Heights, Michigan 48301 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9089 Attachment III - Technical Information Part 1: Axle Rear Axle Lower Control Arm Bracket Inspection and/or Track Bar Bracket Modification Affected Vehicles: 1997 Expedition built at the Michigan Truck Plant from March 1, 1996 through October 10,1996 NOTE: This program contains two parts: Part 1: Axle inspection and, if necessary, replacement Part 2: Track bar bracket inspection/modification NOTE: It is most efficient to perform both inspections before proceeding further. Part 1: Axle Inspection and, If Necessary, Replacement 1. On vehicles equipped with air suspension, turn air suspension switch off. Switch is located in the right side kick panel. 2. Raise and support vehicle. 3. Inspect both rear axle tubes for date code stamps. Clean paint or undercoating to locate date code. See Figure 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9090 ^ It date code stamps are present on both rear axle tubes, no service action is required for the rear axle. Go to PART 2. ^ If date code stamps are not on both rear axle tubes, the rear axle must be replaced. Continue on, to order axle. ^ If inspection reveals that the axle must be replaced, check rear axle ID tag for axle ratio code and ring gear diameter, See Figure 2. ^ Cross reference axle ratio code and ring gear diameter in table below to get axle service part number. See Figure 3. ^ Call RENKIM (1-800-325-5621) to order a new axle. When new rear axle is received, proceed to Rear Axle Replacement. Rear Axle Replacement Vehicles Equipped With Rear Air Suspension (See sections for vehicles with rear coil spring suspension) Removal 1. Lower Vehicle 2. Vent air spring air pressure as follows: ^ Turn air suspension switch on. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9091 ^ Turn the ignition to the run position. ^ Connect the NGS tester to the vehicle. ^ Select 1997 4.6L/5.4L Expedition 4WAS module. ^ Select "Air Suspension Control Mode: under "Active Command Modes" menu. ^ Select "VENT REAR" to deflate rear air springs. ^ Turn air suspension switch off. 3. Install memory saver, then disconnect battery negative terminal. 4. Raise and support vehicle. 5. Remove both rear tire and wheel assemblies. 6. Remove driveshaft retaining bolts, then separate driveshaft from companion flange. 7. Wire driveshaft away from the rear axle. 8. Disconnect rear ABS sensor electrical connector, then detach wiring harness from rear axle. 9. On each side of the vehicle, perform the following: ^ Disconnect parking brake cable from parking brake lever. ^ Separate parking brake cable from disc brake adapter. ^ Remove brake caliper retaining bolts, then position brake caliper away from the rear axle. Do not let caliper hang from the brake hose. ^ Remove O-ring from hub, then remove brake rotor from hub. ^ Remove jounce bumper from axle housing. 10. Remove sway bar retainer-to-rear axle mount retaining bolts. Position sway bar away from rear axle. 11. Disconnect load level sensor from rear axle. 12. Position jack stands under rear axle. 13. Lower vehicle enough to release tension on rear axle attaching points (shock absorbers, control arms). 14. Disconnect track bar from rear axle. Position track bar away from rear axle. 15. On each side of the vehicle, perform the following: ^ Remove upper control arm-to-rear axle retaining bolt. Separate control arm from its mounting. ^ Remove lower control arm-to-rear axle retaining bolt. Separate control arm from its mounting. ^ Remove shock absorber-to-rear axle retaining bolt. Separate shock from its mounting. 16. Disconnect axle vent hose from rear axle. 17. Slowly raise the vehicle. Make sure there are not components that will interfere with vehicle separation from the rear axle. 18. Remove rear axle from jack stands. Installation NOTE: New attaching hardware is provided with the replacement axle assembly. Do not use old attaching hardware. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9092 NOTE: Refer to the table to cross-reference circled letters to part description. 1. Position new rear axle on jack stands. 2. Position differential nose on an upward angle using third jack stand. This will allow control arms to clear axle when vehicle is lowered. 3. Lower vehicle over axle. NOTE: Do not tighten retaining nuts at this time. 4. Connect the following components to the rear axle: ^ Air springs ^ Lower control arms (use bolt [A] and nut [C]). ^ Upper control arms (use bolt [A] and nut [B]). ^ Shock absorbers (use bolt [I] and nut [J]). ^ Sway bar retainers (use bolt [E] and nut [D]). ^ Track bar (use bolt [F] and nut [G]). 5. Raise and support vehicle. 6. Position hydraulic jack under rear axle. 7. Raise rear axle until lower control arms are parallel to the ground. NOTE: Tighten both left and right sides of a component before proceeding to the next component. 8. Tighten the following components: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9093 ^ Lower control arm retaining nuts to 128-172 Nm (95-127 lb/ft). ^ Upper control arm retaining nuts to 128-172 Nm (95-127 lb/ft). ^ Shock absorber lower retaining nuts to 88-119 Nm (65-87 lb/ft). ^ Sway bar retainer bolts to 53-72 Nm (39-53 lb/ft). ^ Track bar retaining nut 170-230 Nm (125-169 lb/ft). 9. Connect axle vent hose to the rear axle. 10. Connect the load level sensor to the rear axle. 11. On each side of the vehicle, perform the following: ^ Connect parking brake cable to the parking brake lever. ^ Connect parking brake cable to the disc brake adapter. ^ Install the brake rotor, then the hub O-ring (use O-ring [L]). ^ Position and install the brake caliper. Tighten the retaining bolts to 27 Nm (20 lb/ft). ^ Install jounce bumper onto the rear axle (use screw [H)). Tighten retaining screw to 34-46 Nm (25-33 lb/ft). 12. Route rear ABS sensor wiring harness, then connect rear ABS sensor electrical connector. 13. Align yellow marks on both the driveshaft and companion flange, then install driveshaft retaining bolts (use bolt [K]). Tighten bolts to 88-119 Nm (65-88 lb/ft). WARNING RETIGHTEN AT 800KM (500 MILES) AFTER ANY WHEEL CHANGE OR ANY TIME THE LUG NUTS ARE LOOSENED. WARNING FAILURE TO RETIGHTEN LUG NUTS AT THE MILEAGE SPECIFIED COULD ALLOW WHEELS TO COME OFF WHILE THE VEHICLE IS IN MOTION, POSSIBLY CAUSING LOSS OF VEHICLE CONTROL AND COLLISION. 14. Install both rear tires and wheel assemblies. Tighten wheel nuts in criss-cross pattern to 115-156 Nm (85-115 lb/ft). 15. Lower Vehicle. 16. Turn on air suspension switch. 17. Start and run vehicle. Make sure air suspension system pressurizes the rear air springs. Rear Coil Spring Suspension Vehicles Equipped With Rear Coil Spring Suspension (See previous section for vehicles with rear air suspension) Removal 1. Remove both rear tire and wheel assemblies. 2. Remove driveshaft retaining bolts, then separate driveshaft from companion flange. 3. Wire drive shaft away from the rear axle. 4. Disconnect rear ABS sensor electrical connector, then detach wiring harness from rear axle. 5. On each side of the vehicle, perform the following: ^ Disconnect parking brake cable from parking brake lever. ^ Separate parking brake cable from disc brake adapter. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9094 ^ Remove brake caliper retaining bolts, then position brake caliper away from the rear axle. Do not let caliper hang from the brake hose. ^ Remove O-ring from hub, then remove brake rotor from hub. ^ Remove jounce bumper from axle housing. 6. Remove sway bar retainer-to-rear axle mount retaining bolts. Position sway bar away from rear axle. 7. Position jack stands under rear axle. 8. Lower vehicle enough to release tension on rear axle attaching points (shock absorbers, control arms). 9. Disconnect track bar from rear axle. Position track bar away from rear axle. 10. On each side of the vehicle, perform the following: ^ Remove upper control arm-to-rear axle retaining bolt. Separate control arm from its mounting. ^ Remove lower control arm-to-rear axle retaining bolt. Separate control arm from its mounting. ^ Remove shock absorber-to-rear axle retaining bolt. Separate shock from its mounting. 11. Disconnect axle vent hose from rear axle. 12. Slowly raise the vehicle. Make sure there are no components that will interfere with vehicle separation from the rear axle. 13. Remove both rear coil springs. 14. Remove rear axle from jack stands. Installation NOTE: New attaching hardware is provided with the replacement axle assembly. Do Not use old attaching hardware. NOTE: Refer to the table to cross-reference circle letters to part description. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9095 1. Position new rear axle on jack stands. 2. Position differential nose on an upward angle using third jack stand. This will allow control arms to clear axle when vehicle is lowered. 3. Lower vehicle over axle. NOTE: Do not tighten retaining nuts at this time. 4. Connect the following components to the rear axle: ^ Lower control arms (use bolt [A] and nut [C]). ^ Upper control arms (use bolt [A] and but [B)). 5. Raise and support vehicle. 6. Position hydraulic lack under rear axle. 7. Raise rear axle until lower control arms are parallel to the ground. NOTE: Tighten both left and right sides of a component before proceeding to the next component. 8. Tighten the following components: ^ Lower control arm retaining nuts to 128-172 Nm (95-127 lb/ft). ^ Upper control arm retaining nuts to 128-172 (95-127 lb/ft). 9. Lower the rear axle until axle is hanging freely from hydraulic jack. 10. Install both coil springs. 11. Raise rear axle, then connect the following components to the rear axle: ^ Shock absorbers (use bolt [I] and nut [J]). ^ Sway bar retainers (use bolt [E] and nut [D]). ^ Track bar (use bolt [F] and nut [G]). NOTE: Tighten both left and right sides of a component before proceeding to the next component. 12. Tighten the following components: ^ Shock absorber lower retaining nuts to 88-119 Nm (65-87 lb/ft). ^ Sway bar retainer bolts to 53-72 Nm (39-53 lb/ft). ^ Track bar retaining nut 170-230 Nm (125-169 lb/ft). 13. Connect axle vent hose to the rear axle. 14. On each side of the vehicle, perform the following: ^ Connect parking brake cable to the parking brake lever. ^ Connect parking brake cable to the disc brake adapter. ^ Install the brake rotor, then the hub O-ring (use O-ring [L]). ^ Position and install the brake caliper. Tighten the retaining bolts to 27 Nm (20 lb/ft). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9096 ^ Install jounce bumper onto the rear axle (use screw [H]). Tighten retaining screw to 34-46 Nm (25-33 lb/ft). 15. Route rear ABS sensor wiring harness, then connect rear ABS sensor electrical connector. 16. Align yellow marks on both the driveshaft and companion flange, then install driveshaft retaining bolts (use bolt [K]). Tighten bolts to 88-119 Nm (65-88 lb/ft). WARNING RETIGHTEN AT 800KM (500 MILES) AFTER ANY WHEEL CHANGE OR ANY TIME THE LUG NUTS ARE LOOSENED. WARNING FAILURE TO RETIGHTEN LUG NUTS AT THE MILEAGE SPECIFIED COULD ALLOW WHEELS TO COME OFF WHILE THE VEHICLE IS IN MOTION, POSSIBLY CAUSING LOSS OF VEHICLE CONTROL AND COLLISION. 17. Install both rear tires and wheel assemblies. Tighten wheel nuts in criss-cross pattern to 115-156 Nm (85-115 lb/ft). 18. Lower vehicle. Attachment III - Technical Information - Part 2: Bar Bracket Rear Axle Lower Control Arm Bracket Inspection and/or Track Bar Bracket Modification Affected Vehicles: 1997 Expedition built at the Michigan Truck Plant from March 1, 1996 through October 10, 1996 NOTE: This program contains two parts: Part 1: Axle inspection and, if necessary, replacement Part 2: Track bar bracket inspection/modification Inspection Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9097 1. Inspect for welds on inside of left track bar bracket. See Figure 4. ^ If welds are present, no track bar bracket service action is required for the vehicle. Lower vehicle and turn air suspension switch on, if equipped. Return vehicle to the customer unless axle is to be replaced. ^ If welds are not present, proceed to Track Bar Bracket Modification. In the rare case where the bracket has been separated from the frame, call Renkim at 1-800-325-5621. Track Bar Bracket Modification 1. Lower vehicle. 2. Remove spare tire assembly. 3. On vehicles equipped with air suspension, vent air spring air pressure as follows: ^ Turn air suspension switch on. ^ Turn the ignition to the run position. ^ Connect the NGS tester to the vehicle. ^ Select 1997 4.6L/5.4L Expedition 4WAS module. ^ Select "Air Suspension Control Mode: under "Active Command Modes" menu. ^ Select "VENT REAR" to deflate rear air springs. ^ Turn air suspension switch off. 4. Install memory saver, then disconnect battery negative cable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9098 5. Raise and support vehicle. 6. Remove both rear tire and wheel assemblies. 7. Remove 0-rings from both rear hubs. 8. Remove inspection cover from left side frame rail above the rear axle. 9. On vehicles equipped with coil spring suspension, remove left rear coil spring as follows: ^ Place hydraulic jack under axle housing. ^ Raise jack slightly to release tension on rear axle components. ^ Remove both rear shock absorber lower mounting bolts. ^ Remove both sway bar to sway bar link retaining bolts. Position sway bar away from links. ^ Lower jack enough to release spring tension. ^ Remove left rear spring. 10. On vehicles equipped with air suspension, remove left rear air spring as follows: ^ Disconnect air spring electrical connector. ^ Disconnect air spring air line. ^ Remove air spring upper and lower retaining clips. ^ Compress air spring as necessary to give enough clearance to remove spring. ^ Remove left rear air spring. 11. Use fan to purge gas vapor from under vehicle. 12. Disconnect and plug EVAP canister vapor line. 13. Disconnect EVAP canister electrical connector. 14. Remove canister retaining nuts, then the canister. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9099 15. Check for outside weld of track bar bracket to frame rail. See Figure 5. NOTE: Perform the following step only if the weld in the previous step is missing. If the weld was present in the previous step, go to Step 17. WARNING POSITION A WELD SHIELD OVER THE FUEL, VAPOR AND BRAKE TUBES IN THE AREA TO BE WELDED. COVER THE SHIELD WITH WET RAGS TO PROTECT IT FROM THE HEAT FROM THE WELDING PROCEDURE. CAUTION Do not use oxy-acetylene torch to weld brackets or frame members. Excessive heat may weaken the metal in the frame members and cause permanent damage. CAUTION As a precaution against damage to electrical components, be sure to disconnect the battery cables before using any welding equipment. Also it is imperative to connect the ground clamp as close to the work area as possible. Perform all welding using Rotunda mig wire feed welder 164-R3667 or equivalent using a 75/25 or 80/20 Argon/CO2 gas mix, and welding wire meeting AWS-E-705 specification. It is essential that the repair welds, particularly on load bearing parts or parts contributing to the strength of the assembly, are equivalent to the original in size, type and strength. 16. To place weld on track bar bracket to frame rail, proceed as follows: ^ Partially lower vehicle. ^ Disconnect positive battery cable from the battery. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9100 ^ Partially raise vehicle. ^ Clean area shown in Figure 6. ^ Using the above recommended or equivalent mig welder, place weld in location shown in Figure 6. The wire in the mig welder should be .035 inch in diameter to weld this location. 17. Install reinforcing plates as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9101 ^ Using supplied reinforcing plate mark location in rear flange of track bar bracket for holes to be drilled out. See Figure 7 and 8. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9102 ^ Using 12 mm drill bit, drill holes in rear flange of track bar bracket. See Figure 9. Make sure to drill straight through the track bar bracket. if holes are drilled on an angle, the inside plate will not line up. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9103 ^ Install two reinforcing plates, bolts and nuts on rear flange of track bar bracket: one on outside of bracket and one inside of crossmember. Tighten to 81.4 Nm (60 lb/ft) and spray with Super Seal Anti-Corrosion Compound or equivalent. See Figure 10. ^ Repeat step 17 on front flange of track bar bracket. 18. On vehicles equipped with air suspension, install left rear air spring as follows: ^ Position air spring in its mountings. ^ Install air spring upper and lower retaining clips. ^ Connect air spring electrical connector. ^ Connect air spring air line. 19. On vehicles equipped with coil spring suspension, install left rear coil spring as follows: ^ Install coil spring in its mountings. ^ Raise jack to position rear axle in its installed position. ^ Position sway bar on sway bar links, then install retaining bolts. Tighten to 86-114 Nm (65-85 lb/ft). ^ Position both rear shock absorbers on their mounting brackets, then install both lower retaining bolts. Tighten bolts to 86-114 Nm (65-85 lb/ft). ^ Remove hydraulic jack. 20. Position EVAP canister on left frame rail, then install retaining nuts. 21. Connect EVAP canister electrical connector. 22. Unplug and connect canister vapor line. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9104 23. Install inspection cover on left side frame rail. 24. Install O-rings on both rear hubs. WARNING RETIGHTEN AT 800KM (500 MILES) AFTER ANY WHEEL CHANGE OR ANY TIME THE LUG NUTS ARE LOOSENED. WARNING FAILURE TO RETIGHTEN LUG NUTS AT THE MILEAGE SPECIFIED COULD ALLOW WHEELS TO COME OFF WHILE THE VEHICLE IS IN MOTION, POSSIBLY CAUSING LOSS OF VEHICLE CONTROL AND COLLISION. 25. Install both rear tire and wheel assemblies. Tighten wheel nuts in criss-cross pattern to 115-156 Nm (85-115 lb/ft). 26. Lower vehicle. 27. Install spare tire. 28. Connect battery cable(s), then remove memory saver. 29. On vehicles equipped with air suspension, turn air suspension switch on. Attachment IV - Revised Technical Instructions Announcing revised Technical Instructions for Safety Recall 96560 (Expedition Rear Axle Lower Control Arm/Track Bar Bracket). The following revisions are necessary because a survey of axles inspected by dealers has revealed that most of these axles did not actually need to be replaced. SUPPLEMENTAL TECHNICAL INSTRUCTIONS: 1. Determine the vehicle build date prior to axle inspection. 2. If vehicle build date is August 10, 1996 or later, no axle inspection and/or replacement is required. However, track bar repairs may still be required for the vehicle. Please begin directly at Step # 4 of the original Technical Instructions if build date is August 10, 1996 or later. 3. If vehicle build date is August 9, 1996 or earlier, please proceed with axle inspection as detailed in the original Technical Instructions EXCEPT AS FOLLOWS: a. Remove the axle identification tape (if present) from the right hand axle tube assembly to reveal the date code stamp. b. If you cannot find date code on both axle tube assemblies, call Ford Axle Hot Line at 1 -800-FORD-AXL (1-800-3673-295) before ordering replacement axle assembly to confirm replacement requirements. Please have vehicle VIN and build date available. c. Upon completion of Axle inspection/replacement, proceed to Step # 4 of the original Technical Instructions for Track Bar repair. 4. When attaching the track bar bracket reinforcement kit (Part Number F75Z-5L005-AA), torque the bolts to 68 Nm (50 lb. ft.), NOT 81.4 Nm (60 lb. ft.). 5. Also, when installing the track bar bracket reinforcement kit, the plates should fit flush to the track bar bracket. As required, excess weld material may need to be ground flush to the bracket. If this is required, submit additional time as "Related Damage". Recall/Service Programs Department March 11, 1997 Attachment V - Revised Technical Instr. and Labor Allowances April 7, 1997 Announcing revised Technical Instructions and Labor Allowances for Safety Recall 96S60 (Expedition Rear Axle Lower Control Arm/Track Bar Bracket). 1. REVISED TECHNICAL INSTRUCTIONS: To simplify the inspection process, inspection for welds inside the left track bar bracket is no longer required. Effective immediately, the Track Bar Retaining Kit is to be installed on all affected vehicles. Remember, when installing the Track Bar Retaining Kit, be sure to torque the bolts to 68 Nm (50 lb.ft.) as noted in our 3/11/97 FAX. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9105 NOTE: Vehicles already reported as INSPECTED only do not have to be returned for the Track Bar Bracket Retaining Kit installation. 2. REVISED LABOR ALLOWANCES: The labor allowances on Attachment II Page 1 of the dealer letter dated February, 1997 have been revised as follows (please annotate your copies appropriately): NOTE: Effective the date of this communication, Labor Operation 96S60A is discontinued because the Track Bar Retaining Bracket Kit is to be installed on all vehicles. Install Track Bar Retaining Plates ONLY (no axle replacement required). (Includes inspection of axle for date codes): NOTE: Also, effective with this communication, Labor Operation 96S60D and Labor Operation 96S60E are discontinued because the Track Bar Retaining Kit is to be installed on all vehicles. Install Track Bar Retaining Plates and new axle assembly. (Includes inspection of axle assembly for date codes): NOTE: Only submit one of the above Labor Operations per vehicle. Be sure to select the correct operation. The labor operations above contain time to re-torque the lug nuts after the 800km (500 mile) interval as recommended in the vehicle Owner Guide. Administrative Allowance - 0.1 Hrs. - Misc. Expense Code "Admin" 3. FOR PREVIOUSLY SUBMITTED CLAIMS: Use the ACESII Online Appeal Procedure to claim the additional time against the original paid repair order that used the previously published labor time. Recall/Service Programs Department April, 1997 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9106 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9107 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Page 9108 Control Arm: Specifications FRONT SUSPENSION Lower Arm Nut ..................................................................................................................................... ............................. 164-200 Nm (121-148 ft. lbs.) Upper Arm Nut ....................................................... ............................................................................................................. 113-153 Nm (83-112 ft. lbs.) Upper Arm Plates Bolts/Nuts ............................................................................................................................................... 113-153 Nm (83-112 ft. lbs.) Upper Arm Cam Bolt ........................................................................................................................................................... 113-153 Nm (84-112 ft. lbs.) REAR SUSPENSION Lower Arm Assembly Axle Bolt .............................................................................................................................................. .......................... 128-172 Nm (94-127 ft. lbs.) Frame Bolt .................................................................. ................................................................................................... 128-172 Nm (94-127 ft. lbs.) Upper Arm Assembly Frame Bolt ........................................................................................................................................... .......................... 128-172 Nm (94-127 ft. lbs.) Axle Bolt ..................................................................... ................................................................................................... 128 172 Nm (94-127 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower Control Arm: Service and Repair Lower REMOVAL 1. Remove the wheel hub. 2. Make preliminary adjustment references. (1) Make an alignment mark on the torsion bar and the torsion bar crossmember support. (2) Measure and record the length. 3. Relieve the torsion bar tension. (1) Remove the torsion bar adjuster bolt. (2) Install Torsion Bar Tool with Torsion Bar Tool Adapters in the B slots on Torsion Bar Tool. (3) Tighten Torsion Bar Tool until the torsion bar adjuster lifts off of the adjuster nut. (4) Remove the torsion bar adjuster nut. (5) Remove Torsion Bar Tool. (6) Remove the torsion bar adjuster. ^ Repeat for the other side. 4. Remove the stabilizer bar link nut from the front suspension lower arm. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower > Page 9111 5. Remove the front shock absorber lower bolt and nut from the front suspension lower arm. 6. Remove the lower ball joint castellated nut. (1) Remove the lower ball joint cotter pin. (2) Remove the lower ball joint castellated nut. 7. Use Pitman Arm Puller to separate the front suspension lower arm from the front wheel knuckle. ^ Separate the front suspension lower arm from the front wheel knuckle. 8. Remove the front suspension lower arm. (1) Remove the two front suspension lower arm nuts. (2) Remove the two front suspension lower arm bolts. (3) Remove the front suspension lower arm and torsion bar as an assembly. 9. Separate the front suspension lower arm from the torsion bar. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower > Page 9112 INSTALLATION 1. Install the front suspension lower arm. (1) Attach the front suspension lower arm to the torsion bar. (2) Install the front suspension lower arm and torsion bar as an assembly. (3) Install the front suspension lower arm bolts and nuts. 2. Install the front suspension arm lower ball joint castellated nut. (1) Position the front wheel knuckle. (2) Install the front suspension arm lower ball joint castellated nut. (3) Install a new cotter pin. 3. Install the front stabilizer bar link to the front suspension lower arm. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower > Page 9113 4. Install the front shock absorber lower bolt and nut to the front suspension lower arm. 5. Load the torsion bar. (1) Install the torsion bar adjuster. (2) Install Torsion Bar Tool with Torsion Bar Tool Adapters in the B slots on the torsion bar tool. (3) Tighten Torsion Bar Tool to load the torsion bar. (4) Install the torsion bar adjuster nut. (5) Install the torsion bar adjuster bolt. (6) Remove Torsion Bar Tool. ^ Turn the torsion bar adjuster until the reference marks align. ^ Repeat for the other side. 6. Install the wheel hub. 7. Adjust the ride height. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower > Page 9114 Control Arm: Service and Repair Upper REMOVAL 1. Loosen the lug nuts. (1) Remove the center cap. (2) With the weight of the vehicle on the wheels, loosen the lug nuts. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and wheel bearings. 2. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 3. Remove the wheel and tire assembly. (1) Remove the lug nuts (2) Remove the wheel and tire assembly. 4. Support the front suspension lower arm. ^ Position a jack under the front suspension lower arm. 5. Mark the position of the camber adjustment cam. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower > Page 9115 6. Safely reposition the anti-lock sensor wire. (1) Remove the bolt. (2) Safely reposition the anti-lock sensor wire. 7. Remove the upper ball joint castellated nut. (1) Remove the upper ball joint cotter pin. (2) Remove the upper ball joint castellated nut. 8. Use Pitman Arm Puller to separate the front suspension upper arm from the front wheel knuckle. 9. Remove the front suspension upper arm. (1) Remove the front suspension upper arm nuts. (2) Remove the front suspension upper arm pivot bolts. (3) Remove the front suspension upper arm. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower > Page 9116 INSTALLATION NOTE: Mark the position of the camber adjustment cam. 1. Install the front suspension upper arm. (1) Position the front suspension upper arm. (2) Install the front suspension upper arm bolts. (3) Install the front suspension upper arm nuts. 2. Install the front suspension arm upper ball joint castellated nut. (1) Position the front wheel knuckle. (2) Install the upper ball joint castellated nut. (3) Install a new cotter pin. 3. Position the anti-lock sensor wire. ^ Install the front brake anti-lock sensor wire bracket bolt. 4. Remove the jack. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower > Page 9117 5. Install the tire and wheel assembly. (1) Position the tire and wheel assembly. (2) Install the lug nuts. (3) Tighten the lug nuts in the sequence indicated. (4) Install the center cap. WARNING: WHEN THE WHEEL IS - INSTALLED, ALWAYS REMOVE ANY CORROSION, DIRT OR FOREIGN MATERIAL THAT MAY BE PRESENT ON THE MOUNTING SURFACES OF THE WHEELS OR THE SURFACES OF THE WHEEL HUB, BRAKE DRUM OR BRAKE ROTOR THAT CONTACTS THE WHEEL. INSTALLING WHEELS WITHOUT PROPER METAL-TO-METAL CONTACT AT THE WHEEL MOUNTING SURFACES CAN CAUSE THE LUG NUT TO LOOSEN AND THE WHEEL TO COME OFF WHILE THE VEHICLE IS IN MOTION, CAUSING LOSS OF CONTROL. RETIGHTEN AT 800 KM (500 MILES) AFTER ANY WHEEL CHANGE OR ANY TIME THE LUG NUTS ARE LOOSENED. FAILURE TO RETIGHTEN LUG NUTS AT THE MILEAGE SPECIFIED COULD ALLOW WHEELS TO COME OFF WHILE THE VEHICLE IS IN MOTION, POSSIBLY CAUSING LOSS OF VEHICLE CONTROL AND COLLISION. 6. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. 7. Check the front end alignment. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Specifications Cross-Member: Specifications Torsion Bar Crossmember Support Bolts .................................................................................................................................. 40-54 Nm (29-39 ft. lbs.) Torsion Bar Crossmember Support Nuts ................................................................................................................................... 53-72 Nm (39-53 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Technical Service Bulletins > Recalls for Lateral Stabilizer Rod: > NHTSA96V252000 > Dec > 96 > Recall 96V252000: Track Bar Bracket Breakage Lateral Stabilizer Rod: Recalls Recall 96V252000: Track Bar Bracket Breakage The rear axle track bar bracket can separate from the frame due to missing welds or inadequate weld penetration. If both brackets separate, the rear axle can move laterally until the tires contact either the frame or the wheel house resulting in either tire damage or a significant reduction in vehicle handling performance. Dealers will install a track bar bracket reinforcement kit and inspection of the axle tubes. The suspect axle tubes do not have a stamped date code on the tube. Axles without date codes on the tubes will be replaced. Owner Notification: Owner notification will begin January 20, 1997. NOTE: Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. 1997 FORD TRUCK EXPEDITION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Lateral Stabilizer Rod: > NHTSA96V252000 > Dec > 96 > Recall 96V252000: Track Bar Bracket Breakage Lateral Stabilizer Rod: All Technical Service Bulletins Recall 96V252000: Track Bar Bracket Breakage The rear axle track bar bracket can separate from the frame due to missing welds or inadequate weld penetration. If both brackets separate, the rear axle can move laterally until the tires contact either the frame or the wheel house resulting in either tire damage or a significant reduction in vehicle handling performance. Dealers will install a track bar bracket reinforcement kit and inspection of the axle tubes. The suspect axle tubes do not have a stamped date code on the tube. Axles without date codes on the tubes will be replaced. Owner Notification: Owner notification will begin January 20, 1997. NOTE: Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. 1997 FORD TRUCK EXPEDITION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair Rear Knuckle: Service and Repair REMOVAL 1. Remove the wheel hub. 2. Make preliminary adjustment references. (1) Make an alignment mark on the torsion bar and the torsion bar crossmember support. (2) Measure and record the length. 3. Relieve the torsion bar tension. (1) Remove the torsion bar adjuster bolt. (2) Install Torsion Bar Tool with Torsion Bar Tool Adapters in the B slots on Torsion Bar Tool. (3) Tighten the Torsion Bar Tool until the torsion bar adjuster lifts off of the adjuster nut. (4) Remove the torsion bar adjuster nut. (5) Remove Torsion Bar Tool. (6) Remove the torsion bar adjuster. ^ Repeat for the other side. 4. Safely reposition the anti-lock sensor wire. (1) Remove the bolt. (2) Safely reposition the anti-lock sensor wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 9137 5. Remove the tie rod end castellated nut. (1) Remove the tie rod end cotter pin. (2) Remove the tie rod end castellated nut. 6. Use Pitman Arm Puller to separate the tie rod end. ^ Separate the tie rod end from the front wheel knuckle. 7. Remove the front shock absorber lower bolt and nut from the front suspension lower arm. 8. Remove the upper ball joint castellated nut. (1) Remove the upper ball joint cotter pin. (2) Remove the upper ball joint castellated nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 9138 9. Use Pitman Arm Puller to separate the front wheel knuckle from the front suspension upper arm. 10. Remove the lower ball joint castellated nut. (1) Remove the lower ball joint cotter pin. (2) Remove the lower ball joint castellated nut. 11. Use Pitman Arm Puller to separate the front suspension lower arm from the front wheel knuckle. ^ Separate the front suspension lower arm from the front wheel knuckle. 12. Remove the front wheel knuckle. CAUTION: Suspend the front wheel driveshaft and joint with wire. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 9139 1. Install the front suspension arm lower ball joint castellated nut. (1) Position the front wheel knuckle. (2) Install the front suspension arm lower ball joint castellated nut. (3) Install a new cotter pin. 2. Install the front suspension arm upper ball joint castellated nut. (1) Position the front wheel knuckle. (2) Install the front suspension arm upper ball joint castellated nut. (3) Install a new cotter pin. 3. Install the front shock absorber lower bolt and nut to the front suspension lower arm. 4. Install the tie rod end castellated nut. (1) Position the tie rod end. (2) Install the tie rod end castellated nut. (3) Install a new cotter pin. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 9140 5. Position the anti-lock sensor wire. ^ Install the front brake anti-lock sensor wire bracket bolt. 6. Load the torsion bar. (1) Install the torsion bar adjuster. (2) Install Torsion Bar Tool with Torsion Bar Tool Adapters in the B slots on the torsion bar tool. (3) Tighten Torsion Bar Tool to load the torsion bar. (4) Install the torsion bar adjuster nut. ^ Install the torsion bar adjuster bolt. (5) Remove Torsion Bar Tool. ^ Turn the torsion bar adjuster until the reference marks align. ^ Repeat for the other side. 7. Install the wheel hub. 8. Adjust the ride height. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations Compressor/Pump Relay: Locations Engine View The Air Suspension Compressor Relay is located near the right headlamp. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 9145 Compressor/Pump Relay: Description and Operation A Solid State Relay is used in the air suspension system for compressor control. The relay incorporates a custom power MOSFET and ceramic hybrid circuitry. The relay switches high current loads in response to low power signals and is controlled by the logic of the control module. The compressor relay is energized by the control module to have high current flow from the battery to the compressor motor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Technical Service Bulletin # 01-12-8 Date: 010625 Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Article No. 01-12-8 06/25/01 ^ SUSPENSION - AIR SUSPENSION - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE ^ ELECTRICAL - LAMP - AIR SUSPENSION LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE FORD: 1997-2001 EXPEDITION LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit a check suspension lamp ON with Diagnostic Trouble Codes (DTC's) B2140 or C2140 even after the Air Suspension switch in the upper RH kick panel has been turned on. This may occur at pre-delivery, following suspension service, or after Air Suspension module replacement. This may be caused by the ride height calibration. ACTION Adjust and/or recalibrate ride height as necessary using the NGS (New Generation Star) Tester. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011208A Recalibrate Ride Height 0.2 Hr. For Rear Air Suspension (R.A.S.) 4X2 Vehicles Only 011208B Recalibrate Ride Height 0.5 Hr. For 4 Wheel Air Suspension (4W.A.S.) (Includes Time To Adjust Torsion Bars 4X4 Vehicles Only) DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000, 390000 Service Procedure NOTE DURING PDI (PRE-DELIVERY INSPECTION) IF "CK SUSP" LIGHT IS ON, PRIOR TO SENDING TO SERVICE, VERIFY SWITCH IN UPPER RIGHT KICK PANEL IS ON. THIS SWITCH IS TURNED OFF DURING VEHICLE SHIPMENT TO PREVENT MODULE FROM SEEKING TRIM HEIGHT WHILE SECURED DOWN FOR TRANSPORT. NOTE AN INADVERTENT B2140 OR C2140 MAY RESULT IF A PARAMETER RESET (CLEAR RIDE HEIGHT) IS SELECTED UNDER NGS ACTIVE COMMANDS, THEN CANCELLED OUT. NOTE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 9154 THE AIR SUSPENSION CONTROL MODULE PART NUMBER IS INTERCHANGEABLE BETWEEN THE REAR AIR SUSPENSION (RAS) AND 4-WHEEL AIR SUSPENSION (4WAS) SYSTEMS, BUT ONCE THE MODULE IS INSTALLED, THE VEHICLE WILL THEN DETERMINE WHETHER VEHICLE IS 4X2 (RAS) OR 4X4 (4WAS) BASED ON VEHICLE HARNESS INPUTS. NOTE MODULES ARE PRE-PROGRAMMED TO SEEK 2.66 VOLTS + 1.02 VOLTS FROM REAR HEIGHT SENSOR (RHGSTEN PARAMETER IDENTIFIER OR PID) AT TRIM HEIGHT. HOWEVER, A NEW OR SWAPPED MODULE REQUIRES CALIBRATION PER STEPS BELOW TO CLEAR A 2140 (INITIALIZATION FAILURE) CODE. NOTE PERFORM 4WAS-AIR SUSP/EVO (ELECTRONIC VARIABLE ORIFICE STEERING) SELF TEST AND MAKE NECESSARY REPAIRS FOR ANY OTHER AIR SUSPENSION DTC'S THAT ARE PRESENT BEFORE ADDRESSING B2140/C2140. WARNING WARNING: BEFORE REPLACING ANY AIR SUSPENSION COMPONENTS, HOISTING, JACKING, OR TOWING, DISCONNECT POWER TO THE SYSTEM BY, TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RIGHT KICK PANEL AREA TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. RAS ONLY - CLEAR 2140 NOTE EVEN RAS (4X2) EQUIPPED VEHICLES REQUIRE STORING RIDE HEIGHT AND TOGGLING FRONT TO "ON" TO CLEAR A CK SUSP LIGHT/214O CODE. THIS ALLOWS THE MODULE TO STORE THE VOLTAGE WITH NO FRONT HEIGHT SENSOR PRESENT, AND MUST BE DONE EVEN WITH CONVENTIONAL (STEEL COIL) FRONT SUSPENSION. 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON", press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step # 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional (on-demand) test is in process. As test completes, verify a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off. 4WAS - CLEAR 2140 DTC - Mechanical NOTE OBSERVE AND REPAIR ANY DAMAGED PARTS OR SYSTEM LEAKS, INSPECTING THE AIR LINE UNION LOCATED UNDER THE BRAKE MASTER CYLINDER FIRST. IF BRAKE FLUID HAS DAMAGED THE LINE, REPLACE THEN REROUTE NEW AIR LINE AWAY FROM AN ORIENTATION DIRECTLY UNDER THE MASTER CYLINDER. BRUSH A SOAPY WATER SOLUTION ON REMAINING SYSTEM CONNECTIONS, INCLUDING INLINE AND "T" UNIONS; AIR LINE RUB POINTS; COMPRESSOR FITTINGS; GATE AND FILL SOLENOIDS; AND AIR SHOCKS/SPRINGS. KEEP IN MIND THAT AIR SPRING LEAKS WHERE THE BAG FOLDS OVER ITSELF MAY NOT BE IMMEDIATELY OBVIOUS WITHOUT CYCLING THE SUSPENSION THROUGH DIFFERENT HEIGHTS. IF AIR BUBBLES ARE DETECTED, REPAIR AS NECESSARY THEN RETEST TO ENSURE LEAK-FREE CONNECTIONS BEFORE COMPLETING THE STEPS BELOW. 1. Bring the vehicle to kneel height by turning ignition key off, gear lever in park, doors closed for up to 30 seconds on level ground. Listen for compressor's vent solenoid to release air from lines before proceeding. Venting should occur within approximately one minute of closing all doors Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 9155 with the key in the "off" position. 2. Erase the module's memory: ^ Trigger 4WAS active commands, PARAMETER RESET (Clear Ride Height) WARNING DO NOT RESET REAR HEIGHT AT THIS TIME! ^ Trigger thru warning message, then toggle FRONT CLR from "OFF" to "ON" Press Cancel NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION! 3. You have now cleared the front kneel voltage stored in the module and B2140 will be present on next key-up. 4. Bleed air from front shocks: ^ Mark existing torsion bar setting, then back off the torsion bar adjustment bolt several turns (until approximately 40 mm (1.5") distance from the bolt head to the bottom surface of the torsion bar adjuster is reached) ^ Select AIR SUSP CNTRL from active command menu (NGS will return to this after previous steps) ^ Trigger VENT FRONT, then wait several seconds for air to vent. Press Cancel to exit. 5. Adjust torsion bars per Workshop Manual section 204-01B. NOTE LEAVE THE NGS CONNECTED IN ACTIVE COMMAND MODES (ENTERED IN STEP 4) 50 THE SYSTEM REMAINS IN DIAGNOSTIC MODE AND NOT OPERATIONAL MODE. 6. Finish by performing the following electrical front height reset steps. 4WAS - CLEAR 2140 DTC - Electrical 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON". press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional on-demand test is in process. As test completes, verity a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off and vehicle height settles out as compressor fills air bladders/shocks. NOTE FOR OTHER AIR SUSPENSION CONCERNS, REFER TO THE APPROPRIATE WORKSHOP MANUAL SECTIONS: 204-05A FOR VEHICLE DYNAMIC SUSPENSION - REAR, OR SECTION 204-05B FOR VEHICLE DYNAMIC SUSPENSION - 4 WHEEL. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 98-25-4 > Dec > 98 > Suspension - Warning Lamp ON/DTC's C1770/C1845 Suspension Control Module: Customer Interest Suspension - Warning Lamp ON/DTC's C1770/C1845 Article No. 98-25-4 12/21/98 SUSPENSION - CHECK SUSPENSION LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) C1770 AND/OR C1845 STORED IN MEMORY - VEHICLES BUILT THROUGH 10/1/1998 LIGHT TRUCK: 1997-99 EXPEDITION 1998-99 NAVIGATOR ISSUE Some vehicles equipped with air suspension may exhibit an intermittent check suspension lamp on and Diagnostic Trouble Code (DTC) C1770 and/or C1845 illuminated. Vehicles with these codes may not exhibit any ride height concerns. This may be caused by the air suspension control module. ACTION Replace the air suspension control module with a revised air suspension control module and recalibrate ride height. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Connect New Generation Star (NGS) Tester and go to Air Suspension menu to retrieve stored codes. Confirm that you have code C1770 and/or C1845 in memory. If you have any other codes, proceed with appropriate pinpoint tests in the 1998 Expedition/Navigator Workshop Manual, Section 204-OSA (Rear) or 204-05B (4-Wheel). 2. With NGS Tester, run the air suspension On-Demand self test. If you have any codes, proceed with appropriate pinpoint tests in the Workshop Manual, Section 204-OSA or 204-05B. 3. With NGS Tester, select Active Command Modes menu and manually raise and lower vehicle per Ride Height Adjustment procedure, 1998 Workshop Manual, Section 204-OSA or 204-05B. Monitor vehicle height changes. If vehicle does not respond, follow pinpoint tests for pneumatic failures. If vehicle does function properly, continue with Step 4. 4. Replace air suspension control module per the 1998 Workshop Manual, Section 204-OSA or 204-05B. NOTE A NEW OR EXCHANGED AIR SUSPENSION CONTROL MODULE REQUIRES THAT THE RIDE HEIGHT ADJUSTMENT CALIBRATION PROCESS BE PERFORMED; REFER TO FRONT RIDE HEIGHT RESETTING-CLEAR B2140 DTC. PART NUMBER PART NAME F7SZ-5A919-DB Air Suspension Module (1997-98) XL1Z-5A919-AA Air Suspension Module (1999) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982504A Perform Diagnostics, Install 1.2 Hrs. Air Suspension Module, And Perform Ride Height Adjustment Calibration Process DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Technical Service Bulletin # 01-12-8 Date: 010625 Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Article No. 01-12-8 06/25/01 ^ SUSPENSION - AIR SUSPENSION - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE ^ ELECTRICAL - LAMP - AIR SUSPENSION LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE FORD: 1997-2001 EXPEDITION LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit a check suspension lamp ON with Diagnostic Trouble Codes (DTC's) B2140 or C2140 even after the Air Suspension switch in the upper RH kick panel has been turned on. This may occur at pre-delivery, following suspension service, or after Air Suspension module replacement. This may be caused by the ride height calibration. ACTION Adjust and/or recalibrate ride height as necessary using the NGS (New Generation Star) Tester. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011208A Recalibrate Ride Height 0.2 Hr. For Rear Air Suspension (R.A.S.) 4X2 Vehicles Only 011208B Recalibrate Ride Height 0.5 Hr. For 4 Wheel Air Suspension (4W.A.S.) (Includes Time To Adjust Torsion Bars 4X4 Vehicles Only) DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000, 390000 Service Procedure NOTE DURING PDI (PRE-DELIVERY INSPECTION) IF "CK SUSP" LIGHT IS ON, PRIOR TO SENDING TO SERVICE, VERIFY SWITCH IN UPPER RIGHT KICK PANEL IS ON. THIS SWITCH IS TURNED OFF DURING VEHICLE SHIPMENT TO PREVENT MODULE FROM SEEKING TRIM HEIGHT WHILE SECURED DOWN FOR TRANSPORT. NOTE AN INADVERTENT B2140 OR C2140 MAY RESULT IF A PARAMETER RESET (CLEAR RIDE HEIGHT) IS SELECTED UNDER NGS ACTIVE COMMANDS, THEN CANCELLED OUT. NOTE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 9165 THE AIR SUSPENSION CONTROL MODULE PART NUMBER IS INTERCHANGEABLE BETWEEN THE REAR AIR SUSPENSION (RAS) AND 4-WHEEL AIR SUSPENSION (4WAS) SYSTEMS, BUT ONCE THE MODULE IS INSTALLED, THE VEHICLE WILL THEN DETERMINE WHETHER VEHICLE IS 4X2 (RAS) OR 4X4 (4WAS) BASED ON VEHICLE HARNESS INPUTS. NOTE MODULES ARE PRE-PROGRAMMED TO SEEK 2.66 VOLTS + 1.02 VOLTS FROM REAR HEIGHT SENSOR (RHGSTEN PARAMETER IDENTIFIER OR PID) AT TRIM HEIGHT. HOWEVER, A NEW OR SWAPPED MODULE REQUIRES CALIBRATION PER STEPS BELOW TO CLEAR A 2140 (INITIALIZATION FAILURE) CODE. NOTE PERFORM 4WAS-AIR SUSP/EVO (ELECTRONIC VARIABLE ORIFICE STEERING) SELF TEST AND MAKE NECESSARY REPAIRS FOR ANY OTHER AIR SUSPENSION DTC'S THAT ARE PRESENT BEFORE ADDRESSING B2140/C2140. WARNING WARNING: BEFORE REPLACING ANY AIR SUSPENSION COMPONENTS, HOISTING, JACKING, OR TOWING, DISCONNECT POWER TO THE SYSTEM BY, TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RIGHT KICK PANEL AREA TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. RAS ONLY - CLEAR 2140 NOTE EVEN RAS (4X2) EQUIPPED VEHICLES REQUIRE STORING RIDE HEIGHT AND TOGGLING FRONT TO "ON" TO CLEAR A CK SUSP LIGHT/214O CODE. THIS ALLOWS THE MODULE TO STORE THE VOLTAGE WITH NO FRONT HEIGHT SENSOR PRESENT, AND MUST BE DONE EVEN WITH CONVENTIONAL (STEEL COIL) FRONT SUSPENSION. 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON", press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step # 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional (on-demand) test is in process. As test completes, verify a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off. 4WAS - CLEAR 2140 DTC - Mechanical NOTE OBSERVE AND REPAIR ANY DAMAGED PARTS OR SYSTEM LEAKS, INSPECTING THE AIR LINE UNION LOCATED UNDER THE BRAKE MASTER CYLINDER FIRST. IF BRAKE FLUID HAS DAMAGED THE LINE, REPLACE THEN REROUTE NEW AIR LINE AWAY FROM AN ORIENTATION DIRECTLY UNDER THE MASTER CYLINDER. BRUSH A SOAPY WATER SOLUTION ON REMAINING SYSTEM CONNECTIONS, INCLUDING INLINE AND "T" UNIONS; AIR LINE RUB POINTS; COMPRESSOR FITTINGS; GATE AND FILL SOLENOIDS; AND AIR SHOCKS/SPRINGS. KEEP IN MIND THAT AIR SPRING LEAKS WHERE THE BAG FOLDS OVER ITSELF MAY NOT BE IMMEDIATELY OBVIOUS WITHOUT CYCLING THE SUSPENSION THROUGH DIFFERENT HEIGHTS. IF AIR BUBBLES ARE DETECTED, REPAIR AS NECESSARY THEN RETEST TO ENSURE LEAK-FREE CONNECTIONS BEFORE COMPLETING THE STEPS BELOW. 1. Bring the vehicle to kneel height by turning ignition key off, gear lever in park, doors closed for up to 30 seconds on level ground. Listen for compressor's vent solenoid to release air from lines before proceeding. Venting should occur within approximately one minute of closing all doors Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 9166 with the key in the "off" position. 2. Erase the module's memory: ^ Trigger 4WAS active commands, PARAMETER RESET (Clear Ride Height) WARNING DO NOT RESET REAR HEIGHT AT THIS TIME! ^ Trigger thru warning message, then toggle FRONT CLR from "OFF" to "ON" Press Cancel NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION! 3. You have now cleared the front kneel voltage stored in the module and B2140 will be present on next key-up. 4. Bleed air from front shocks: ^ Mark existing torsion bar setting, then back off the torsion bar adjustment bolt several turns (until approximately 40 mm (1.5") distance from the bolt head to the bottom surface of the torsion bar adjuster is reached) ^ Select AIR SUSP CNTRL from active command menu (NGS will return to this after previous steps) ^ Trigger VENT FRONT, then wait several seconds for air to vent. Press Cancel to exit. 5. Adjust torsion bars per Workshop Manual section 204-01B. NOTE LEAVE THE NGS CONNECTED IN ACTIVE COMMAND MODES (ENTERED IN STEP 4) 50 THE SYSTEM REMAINS IN DIAGNOSTIC MODE AND NOT OPERATIONAL MODE. 6. Finish by performing the following electrical front height reset steps. 4WAS - CLEAR 2140 DTC - Electrical 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON". press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional on-demand test is in process. As test completes, verity a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off and vehicle height settles out as compressor fills air bladders/shocks. NOTE FOR OTHER AIR SUSPENSION CONCERNS, REFER TO THE APPROPRIATE WORKSHOP MANUAL SECTIONS: 204-05A FOR VEHICLE DYNAMIC SUSPENSION - REAR, OR SECTION 204-05B FOR VEHICLE DYNAMIC SUSPENSION - 4 WHEEL. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 98-25-4 > Dec > 98 > Suspension - Warning Lamp ON/DTC's C1770/C1845 Suspension Control Module: All Technical Service Bulletins Suspension - Warning Lamp ON/DTC's C1770/C1845 Article No. 98-25-4 12/21/98 SUSPENSION - CHECK SUSPENSION LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) C1770 AND/OR C1845 STORED IN MEMORY - VEHICLES BUILT THROUGH 10/1/1998 LIGHT TRUCK: 1997-99 EXPEDITION 1998-99 NAVIGATOR ISSUE Some vehicles equipped with air suspension may exhibit an intermittent check suspension lamp on and Diagnostic Trouble Code (DTC) C1770 and/or C1845 illuminated. Vehicles with these codes may not exhibit any ride height concerns. This may be caused by the air suspension control module. ACTION Replace the air suspension control module with a revised air suspension control module and recalibrate ride height. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Connect New Generation Star (NGS) Tester and go to Air Suspension menu to retrieve stored codes. Confirm that you have code C1770 and/or C1845 in memory. If you have any other codes, proceed with appropriate pinpoint tests in the 1998 Expedition/Navigator Workshop Manual, Section 204-OSA (Rear) or 204-05B (4-Wheel). 2. With NGS Tester, run the air suspension On-Demand self test. If you have any codes, proceed with appropriate pinpoint tests in the Workshop Manual, Section 204-OSA or 204-05B. 3. With NGS Tester, select Active Command Modes menu and manually raise and lower vehicle per Ride Height Adjustment procedure, 1998 Workshop Manual, Section 204-OSA or 204-05B. Monitor vehicle height changes. If vehicle does not respond, follow pinpoint tests for pneumatic failures. If vehicle does function properly, continue with Step 4. 4. Replace air suspension control module per the 1998 Workshop Manual, Section 204-OSA or 204-05B. NOTE A NEW OR EXCHANGED AIR SUSPENSION CONTROL MODULE REQUIRES THAT THE RIDE HEIGHT ADJUSTMENT CALIBRATION PROCESS BE PERFORMED; REFER TO FRONT RIDE HEIGHT RESETTING-CLEAR B2140 DTC. PART NUMBER PART NAME F7SZ-5A919-DB Air Suspension Module (1997-98) XL1Z-5A919-AA Air Suspension Module (1999) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982504A Perform Diagnostics, Install 1.2 Hrs. Air Suspension Module, And Perform Ride Height Adjustment Calibration Process DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations > Electronic Level Control (ELC) Module Suspension Control Module: Locations Electronic Level Control (ELC) Module Instrument Panel View The 4 Wheel Air-Suspension Module is located behind the center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations > Electronic Level Control (ELC) Module > Page 9173 Suspension Control Module: Locations Suspension Control Module Instrument Panel View The 4 Wheel Air-Suspension Module is located behind the center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Diagrams > Electronic Level Control (ELC) Module Suspension Control Module: Diagrams Electronic Level Control (ELC) Module 4 Wheel Air Suspension Module (C295) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Diagrams > Electronic Level Control (ELC) Module > Page 9176 4 Wheel Air Suspension Module (C296) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Diagrams > Electronic Level Control (ELC) Module > Page 9177 Suspension Control Module: Diagrams Suspension Control Module 4 Wheel Air Suspension Module (C295) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Diagrams > Electronic Level Control (ELC) Module > Page 9178 4 Wheel Air Suspension Module (C296) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Description and Operation > Four Wheel Air Suspension Suspension Control Module: Description and Operation Four Wheel Air Suspension A microcontroller-based electronic module controls the air compressor motor (through a solid state relay), and all system solenoids. The module also provides power to front and rear height sensors. The module controls vehicle height adjustments by monitoring the two height sensors, vehicle speed, a steering sensor, acceleration input, the door ajar signal, transfer case signals, and the brake switch. The module also conducts all fail-safe and diagnostic strategies and contains self-test and communication software for testing of the vehicle and related components. The control module is mounted in the passenger compartment inside the instrument panel, above the radio and temperature controls. The air suspension system control module monitors and controls the system through a 32-pin two-way connector. The control module is keyed so that it cannot be plugged into an incorrect harness. There are two sides of the harness connection to the module. Each is uniquely colored and keyed to prevent reversing the connections. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Description and Operation > Four Wheel Air Suspension > Page 9181 Suspension Control Module: Description and Operation Rear Air Suspension A microcontroller-based electronic module controls the air compressor motor (through a solid state relay), and all system solenoids. The module also provides power to the rear height sensor. The module controls vehicle height adjustments by monitoring the one height sensor, vehicle speed, a steering sensor, acceleration input, the door ajar signal, transfer case signals, and the brake switch. The module also conducts all fail-safe and diagnostic strategies and contains self-test and communication software for testing of the vehicle and related components. The control module is mounted in the passenger compartment inside the instrument panel, above the radio and temperature controls. The air suspension system control module monitors and controls the system through a 32-pin two-way connector. The control module is keyed so that it cannot be plugged into an incorrect harness. There are two sides of the harness connection to the module. Each is uniquely colored and keyed to prevent reversing the connections. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Service and Repair > Four Wheel Air Suspension Suspension Control Module: Service and Repair Four Wheel Air Suspension REMOVAL 1. Disconnect battery ground cable. 2. Remove the center instrument panel finish panel. 4 3. Disconnect the transfer case rotary control switch electrical connector. 4. Remove the steering column cover trim panel. 5. Remove the headlamp switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Service and Repair > Four Wheel Air Suspension > Page 9184 6. Remove the LH instrument panel finish panel. (1) Remove the screws. (2) Remove the instrument panel finish panel. 7. Remove the instrument cluster panel. (1) Remove the screws. (2) Remove the instrument cluster panel. 8. Remove the control module mounting bracket screws. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Service and Repair > Four Wheel Air Suspension > Page 9185 9. Lift control module and mounting bracket from instrument panel and disconnect the control module electrical connectors. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Service and Repair > Four Wheel Air Suspension > Page 9186 Suspension Control Module: Service and Repair Rear Air Suspension REMOVAL 1. Disconnect battery ground cable. 2. Remove the center instrument panel finish panel. 3. Remove the steering column cover trim panel. 4. Remove the headlamp switch. 5. Remove the LH instrument panel finish panel. (1) Remove the screws. (2) Remove the instrument panel finish panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Service and Repair > Four Wheel Air Suspension > Page 9187 6. Remove the instrument chaster panel. (1) Remove the screws. (2) Remove the instrument cluster panel. 7. Remove the control module mounting bracket screws. 8. Lift the control module and mounting bracket from the instrument panel and disconnect the control module electrical connectors. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Front Ride Height Sensor: Locations Front Body View The Front Height Sensor is located behind left running broad. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Front > Page 9193 Ride Height Sensor: Locations Rear Body View The Rear Height Sensor is located at rear floor panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Description and Operation > Four Wheel Air Suspension Ride Height Sensor: Description and Operation Four Wheel Air Suspension Two height sensors are mounted on the vehicle. The sensors send a voltage signal to the control module. The output ranges from approximately 4.75 volts at minimum height (when the vehicle is low or in full jounce), to 0.25 volts at maximum height (when the vehicle is high or in full rebound). The sensors have a useable range of 80 mm (3 in) compared to total suspension travel of 200-250 mm (8-10 in) at the wheel. Therefore, the sensors are mounted to the suspension at a point where full suspension travel at the wheel is relative to 80 mm (3 in) of travel at the height sensor. The front height sensor upper socket is attached to the bracket to the frame at the upper control arm mounting area and the lower height sensor socket is attached to the upper control arm bracket. The rear height sensor is attached between the No. 5 frame crossmember (upper socket) and the panhard rod (lower socket). Replace a sensor as a unit. When the height sensor gets shorter the vehicle is lowered and this will cause the air compressor to turn on and pump compressed air to the system. When the sensor gets longer the vehicle is being raised and this will cause the air to be vented from the system to lower the vehicle to its trim height level. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Description and Operation > Four Wheel Air Suspension > Page 9196 Ride Height Sensor: Description and Operation Rear Air Suspension When the height sensor gets shorter the rear of the vehicle is lowered and this will cause the air compressor to turn on and pump compressed air to the air springs. When the sensor gets longer the rear of the vehicle is being raised and this will cause the air to be vented from the air springs to lower the vehicle back to its trim height level. One height sensor is mounted on the vehicle. The sensor sends a voltage signal to the control module. The output ranges from approximately 4.75 volts at minimum height (when the vehicle is low or in full jounce), to 0.25 volts at maximum height (when the vehicle is high or in full rebound). The sensor has a useable range of 80 mm (3 in) compared to total suspension travel of 200-250 mm (8 to 10 in) at the wheel. Therefore, the sensor is mounted to the suspension at a point where full rear suspension travel at the wheel is relative to 80 mm of travel at the height sensor. The rear height sensor is attached between the No. 5 frame crossmember (upper socket) and the panhard rod (lower socket). Replace the sensor as a unit. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Adjustments > Inflate and Deflate the Air Suspension System Ride Height Sensor: Adjustments Inflate and Deflate the Air Suspension System 1. Turn the ignition to the run position. WARNING: DO NOT REMOVE AN AIR SPRING UNDER ANY CIRCUMSTANCES WHEN THERE IS PRESSURE IN THE AIR SPRING. DO NOT REMOVE ANY COMPONENTS SUPPORTING AN AIR SPRING WITHOUT EITHER EXHAUSTING THE AIR OR PROVIDING SUPPORT FOR THE AIR SPRING TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. 2. Connect NGS tester to vehicle. 3. Select 1997 4.6L/5.4L Expedition 4WAS module. 4. Select "Air Suspension Control Mode" under "Active Command Modes" menu. (1) Select "VENT REAR" to deflate rear air springs. (2) Select "LIFT REAR" to inflate rear air springs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Adjustments > Inflate and Deflate the Air Suspension System > Page 9199 Ride Height Sensor: Adjustments Rear Height Resetting Procedure 1. Turn ignition key on. 2. Connect NGS tester to the vehicle. 3. Select 1997 4.6L/5.4L Expedition-4WAS module. 4. Measure vehicle rear height (driver side) from the bottom of the frame to the rear jounce bumper bolt rear side of head base. 5. By using NGS tester "active command modes", adjust rear height to 146.8 +/- 2 mm by moving rear of the vehicle down "VENT REAR" or moving rear of the vehicle up "LIFT REAR." 6. Monitor on the right side of the NGS screen rear height sensor voltage. 7. Loosen the ball stud nut on rear height sensor bracket on track bar and adjust by moving with height sensor up or down until rear height sensor voltage is 2.61 +/- 0.03 volt. 8. Tighten nut to specifications. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Adjustments > Page 9200 Ride Height Sensor: Service and Repair REMOVAL 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO S O MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Remove the air suspension height sensor. (1) Disconnect electrical connector. (2) Depress the metal retaining tabs and remove the air suspension height sensor from the ball studs. NOTE: The air suspension height sensor has a plastic harness retainer to suspension that must be unclipped prior to removal. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations Steering Angle Sensor: Locations Instrument Panel View The Steering Wheel Rotation Sensor is located behind steering wheel in the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 9204 Steering Angle Sensor: Description and Operation The steering sensor is mounted inside the passenger compartment on the steering column. It provides steering rate and position to the control module through two signals: Steering Sensor A and Steering Sensor B. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications Suspension Mode Switch: Specifications Switch Bracket Mounting Bolt ........................................................................................................................................... 10.2-13.8 Nm (91-123 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications > Page 9208 Suspension Mode Switch: Description and Operation The air suspension switch is located behind the RH kick panel on a mounting bracket. The switch interrupts power to the control module. The air suspension switch supplies a signal to the control module. Without the control module receiving this signal the load leveling system is inoperative and will not react when rear of the vehicle is raised or lowered. If the air suspension is disabled by turning off air suspension switch, a "CHECK SUSP" will appear in the RH corner of the cluster with the ignition in the run position. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications > Page 9209 Suspension Mode Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front door scuff plate. 3. Remove the cowl side trim panel. 4. Disconnect the air suspension switch electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications > Page 9210 5. Remove the air suspension switch bracket mounting bolt. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Technical Service Bulletins > Customer Interest: > 98-15-15 > Aug > 98 > Front Suspension Clunking Noise Stabilizer Bushing: Customer Interest Front Suspension - Clunking Noise Article No. 98-15-15 08/03/98 ^ SUSPENSION - "CLUNKING" NOISE HEARD FROM FRONT END - VEHICLES BUILT THROUGH 4/8/98 - 4X4 ONLY ^ NOISE - "CLUNKING" HEARD FROM FRONT END - VEHICLES BUILT THROUGH 4/8/98 - 4X4 ONLY LIGHT TRUCK: 1997-98 EXPEDITION 1998 NAVIGATOR This TSB article is being republished in its entirety to clarify that this article pertains to 4X4 vehicles only. ISSUE A "clunking" noise may be heard from the front end on some vehicles. This may be caused by the front stabilizer bar contacting the frame. ACTION Replace stabilizer bar and stabilizer bar insulators with revised service parts. Refer to the 1998 Expedition/Navigator Workshop Manual, Page 204-01B-21, for details. PART NUMBER PART NAME XL1Z-5482-CA Stabilizer Bar XL1Z-5484-GA Stabilizer bar insulator (2 Required) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-10-10 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 981515A Replace Stabilizer Bar And 1.3 Hrs. Insulators DEALER CODING CONDITION BASIC PART NO. CODE 5482 33 OASIS CODES:303000, 304000, 702000, 702100, 702300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-15-15 > Aug > 98 > Front Suspension - Clunking Noise Stabilizer Bushing: All Technical Service Bulletins Front Suspension - Clunking Noise Article No. 98-15-15 08/03/98 ^ SUSPENSION - "CLUNKING" NOISE HEARD FROM FRONT END - VEHICLES BUILT THROUGH 4/8/98 - 4X4 ONLY ^ NOISE - "CLUNKING" HEARD FROM FRONT END - VEHICLES BUILT THROUGH 4/8/98 - 4X4 ONLY LIGHT TRUCK: 1997-98 EXPEDITION 1998 NAVIGATOR This TSB article is being republished in its entirety to clarify that this article pertains to 4X4 vehicles only. ISSUE A "clunking" noise may be heard from the front end on some vehicles. This may be caused by the front stabilizer bar contacting the frame. ACTION Replace stabilizer bar and stabilizer bar insulators with revised service parts. Refer to the 1998 Expedition/Navigator Workshop Manual, Page 204-01B-21, for details. PART NUMBER PART NAME XL1Z-5482-CA Stabilizer Bar XL1Z-5484-GA Stabilizer bar insulator (2 Required) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-10-10 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 981515A Replace Stabilizer Bar And 1.3 Hrs. Insulators DEALER CODING CONDITION BASIC PART NO. CODE 5482 33 OASIS CODES:303000, 304000, 702000, 702100, 702300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Stabilizer Bushing: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions Four Wheel Drive Selector Switch: All Technical Service Bulletins Transfer Case - Multiple Electrical Malfunctions Article No. 01-16-6 08/20/01 ^ LAMP - 4X4 "LOW RANGE" LIGHT DIMLY LIT ^ SWITCHES - TRANSFER CASE MODE SWITCH - 4X4 HI/LOW SWITCH SHORTED OUT ^ WINDSHIELD WIPERS - INTERMITTENT WIPERS ERRATIC OR INOPERABLE ^ TRANSFER CASE - WATER PRESENT IN TRANSFER CASE FORD: 1997 EXPEDITION, F-150, F-250 LD This article is being republished in its entirety to update the labor time. ISSUE Water may be present in the transfer case on some vehicles. This may cause: ^ Transfer Case Mode Switch to become inoperative ^ The 4X4 "Low Range" light to appear dimly lit ^ The intermittent wipers to become erratic or inoperative ^ Vehicle Speed Sensor (VSS) Diagnostic Trouble Codes (DTCs) P0500, P0503, P1500, and P1501 to be set. This may be caused by water splashing into the transfer case through the vent tube assembly, possibly causing the transfer case mode switch to short out, and/or the VSS gear to swell and set the VSS DTCs listed above. Shorting out the transfer case mode switch may cause the intermittent wiper mode to function erratically, as well as possibly causing the 4X4 light to work incorrectly. ACTION Inspect, diagnose, and/or replace the necessary components. Refer to the following Service Procedure for details. SERVICE PROCEDURE Procedure for VSS Gear: 1. Inspect VSS gear in the transfer case for looseness. 2. Replace Gear (C80Z-17285-B) as necessary. Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Mode Switch: 1. Check resistance of the Transfer Case Mode Switch. 2. The resistance of the switch should be at least 100,000 ohms. If it is less, replace the switch (3-Position Switch, E7TZ-7E440-A, manual shift only). Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Vent Replacement: 1. Remove old vent hose from fitting on front of transfer case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Stabilizer Bushing: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 9230 2. Attach end of new Vent Hose (F75Z-7A246-M) to fitting, and route the hose up over the top of the transfer case (Figure 1). 3. Attach the clip on the vent hose to the top of the vertical rib on the transfer case extension housing to support the end of the hose (Figure 2). NOTE FOR ALL WATER CONCERNS, DRAIN AND REFILL THE TRANSFER CASE WITH FRESH FLUID (XT-2-QDX), AND REPLACE THE VENT HOSE WITH THE REVISED PART. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Stabilizer Bushing: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 9231 SUPERSEDES:97-11-19 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011606A Drain And Refill Transfer 1.2 Hrs. Case, Inspect And/Or Replace VSS Gear And Transfer Case Mode Switch, And Install Vent Kit DEALER CODING CONDITION BASIC PART NO. CODE 7D494 49 OASIS CODES: 202000, 206000, 508000, 508300, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Stabilizer Bushing: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 9237 2. Attach end of new Vent Hose (F75Z-7A246-M) to fitting, and route the hose up over the top of the transfer case (Figure 1). 3. Attach the clip on the vent hose to the top of the vertical rib on the transfer case extension housing to support the end of the hose (Figure 2). NOTE FOR ALL WATER CONCERNS, DRAIN AND REFILL THE TRANSFER CASE WITH FRESH FLUID (XT-2-QDX), AND REPLACE THE VENT HOSE WITH THE REVISED PART. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Stabilizer Bushing: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 9238 SUPERSEDES:97-11-19 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011606A Drain And Refill Transfer 1.2 Hrs. Case, Inspect And/Or Replace VSS Gear And Transfer Case Mode Switch, And Install Vent Kit DEALER CODING CONDITION BASIC PART NO. CODE 7D494 49 OASIS CODES: 202000, 206000, 508000, 508300, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > Customer Interest for Stabilizer Link: > 97-26-25 > Dec > 97 > Rear Sway Bar Link - Clunking/Rattling Noise Stabilizer Link: Customer Interest Rear Sway Bar Link - Clunking/Rattling Noise Article No. 97-26-25 12/22/97 NOISE - "CLUNKING/RATTLING" NOISE COMING FROM REAR OF VEHICLE - VEHICLES BUILT THROUGH 4/11/97 LIGHT TRUCK: 1997 EXPEDITION ISSUE: A "clunking/rattling" noise may be heard from the rear of the vehicle when going over bumps. This may be caused by a bushing falling out of the rear sway bar link. ACTION: Replace the sway bar ink and install a washer onto the sway bar link. The washer should reduce the possibility of the bushing coming off of the sway bar link. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Replace the rear Sway Bar Link (F75Z-5K484-AA) and install a Washer (N800916-S100) on the end of the bolt that holds the link to the frame. Refer to the 1998 Expedition Workshop Manual for correct replacement procedures. 2. Torque the bolt to 103 N.m (76 lb-ft). 3. Repeat this for the opposite side of the vehicle. PART NUMBER PART NAME F75Z-5K484-AA Sway Bar Link N800916-S100 Washer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 972625AT Replace Link And Washer 0.5 Hr. - Both Sides 972625A Replace Link And Washer 0.4 Hr. - One Side DEALER CODING CONDITION BASIC PART NO. CODE 5K484 12 OASIS CODES: 303000, 304000, 305000, 702200, 702300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Stabilizer Link: > 97-26-25 > Dec > 97 > Rear Sway Bar Link - Clunking/Rattling Noise Stabilizer Link: All Technical Service Bulletins Rear Sway Bar Link - Clunking/Rattling Noise Article No. 97-26-25 12/22/97 NOISE - "CLUNKING/RATTLING" NOISE COMING FROM REAR OF VEHICLE - VEHICLES BUILT THROUGH 4/11/97 LIGHT TRUCK: 1997 EXPEDITION ISSUE: A "clunking/rattling" noise may be heard from the rear of the vehicle when going over bumps. This may be caused by a bushing falling out of the rear sway bar link. ACTION: Replace the sway bar ink and install a washer onto the sway bar link. The washer should reduce the possibility of the bushing coming off of the sway bar link. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Replace the rear Sway Bar Link (F75Z-5K484-AA) and install a Washer (N800916-S100) on the end of the bolt that holds the link to the frame. Refer to the 1998 Expedition Workshop Manual for correct replacement procedures. 2. Torque the bolt to 103 N.m (76 lb-ft). 3. Repeat this for the opposite side of the vehicle. PART NUMBER PART NAME F75Z-5K484-AA Sway Bar Link N800916-S100 Washer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 972625AT Replace Link And Washer 0.5 Hr. - Both Sides 972625A Replace Link And Washer 0.4 Hr. - One Side DEALER CODING CONDITION BASIC PART NO. CODE 5K484 12 OASIS CODES: 303000, 304000, 305000, 702200, 702300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Dryer, Suspension Control > Component Information > Technical Service Bulletins > Air Suspension - Repeat Compressor Drier Failures Air Dryer: Technical Service Bulletins Air Suspension - Repeat Compressor Drier Failures Article No. 03-9-2 05/12/03 ^ SUSPENSION - REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES ^ ELECTRICAL - REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES FORD: 1997-2002 EXPEDITION LINCOLN: 1998-2002 NAVIGATOR Article 03-7-9 is being republished in its entirety to update the Service Procedure. ISSUE Some 1997-2002 Expedition 4X4 and 1998-2002 Navigator 4X4 vehicles equipped with 4-wheel air suspension, may exhibit repeat air compressor drier failures. The drier cap may become detached from the drier body, or the drier body may be broken at the neck near the compressor head. This may be due to incomplete or incorrect system diagnosis that leads to replacement of only the original air suspension compressor, despite the fact that the compressor is not the root cause of the concern. Compressor failure in these instances is only a symptom of an underlying system problem. ACTION Refer to the service information contained in this TSB for information on proper diagnosis of system issues. Be sure to check the system for proper pneumatic function as described during service to ensure a robust repair. SERVICE INFORMATION Overview Proper pneumatic function can be tested by verifying that both the front AND the rear of the vehicle can be raised and lowered one inch using a scan tool, and by monitoring the height sensor PIDs for movement while the vehicle is in the service bay. If the vehicle does not raise and lower normally, check the solenoid valves and air lines for blockages and/or restrictions. Replace any blocked or restricted solenoids and air lines. ALWAYS check for proper pneumatic function before returning the vehicle back to the customer. NOTE DISCONNECTING AN AIR LINE THAT IS CONNECTED TO THE AIR COMPRESSOR CAN CAUSE PERSONAL INJURY OR DAMAGE TO COMPONENTS AS HIGH PRESSURE IS VENTED UNCONTROLLED. If diagnostics lead to compressor/dryer assembly replacement, use the following service procedure to insure complete and thorough service. 1. Using the New Generation STAR (NGS) tester, vent the compressor/drier assembly. 2. Using regulated shop air, blow out the air lines from the drier to the front fill solenoid valve and from the drier to the rear fill solenoid valve, before installing the new compressor assembly. 3. Replace the air suspension compressor assembly. Refer to Workshop Manual Section 204-05 for compressor installation instructions. 4. Replace the front fill solenoid. Refer to Workshop Manual Section 204-05 for replacement instructions. The front fill solenoid must be replaced because in these cases, it may have sustained damage from the drier desiccant or other contaminants. 5. Connect the New Generation STAR (NGS) tester to the vehicle while the vehicle is parked in the service bay with the engine running. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Dryer, Suspension Control > Component Information > Technical Service Bulletins > Air Suspension - Repeat Compressor Drier Failures > Page 9257 6. Install a pressure gauge capable of reading 400 PSI at the front air line (Figure 1). Using the scan tool, command the compressor ON. Check the output of the compressor on the gauge: a. If the compressor does not output at least 110 PSI within 30 seconds, replace the compressor again and retest. NOTE VERIFY THAT THE SUSPENSION RAISES PROPERLY. 7. Using the scan tool, command the front of the vehicle to raise up one inch. The front suspension should rise one inch in 25 seconds or less. a. If the compressor output is near 300 PSI, check4or air line or solenoid restrictions, repair as necessary and retest. Otherwise, proceed to Step 7b. NOTE SUSPENSION UPWARD MOVEMENT CAN BE VERIFIED BY MONITORING EITHER OF THE FRONT HEIGHT SENSOR PIDS, WHICH SHOULD DECREASE BY .35 TO .45 VOLTS. b. If the front of the vehicle DOES NOT raise, check the front pneumatic system for leaks, inoperable or blocked solenoid valves or pinched air lines. If an issue is found, repair as required and repeat Step 7 to verify proper operation. c. If no problem found, continue to Step 8. NOTE VERIFY THAT SUSPENSION PROPERLY. 8. If the front of the vehicle DOES raise, use the scan tool to command the front of the vehicle to lower one inch. The front suspension should lower one inch in 20 seconds or less. NOTE SUSPENSION DOWNWARD MOVEMENT CAN BE VERIFIED BY MONITORING EITHER OF THE FRONT HEIGHT SENSOR PIDS, WHICH SHOULD INCREASE BY .35 TO .45 VOLTS. a. If the front of the vehicle DOES NOT lower, check the front pneumatic system for leaks, inoperable or blocked solenoid valves, an inoperable vent solenoid, or pinched air lines. Repair air lines or replace solenoid valves as required. 9. Repeat Steps 7 and 8 for the rear. Command the rear of the vehicle, and monitor the rear height sensor PID. Voltages should increase when the vehicle is lowered, and decrease when the vehicle is raised. If the rear of the vehicle does not raise and lower as commanded, inspect the rear pneumatic system for leaks, inoperable or blocked solenoid valves, an inoperable vent solenoid, or pinched air lines, and repair as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Dryer, Suspension Control > Component Information > Technical Service Bulletins > Air Suspension - Repeat Compressor Drier Failures > Page 9258 10. If the vehicle raises and lowers normally in both the front and the rear, test drive the vehicle to confirm the repair. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-7-9 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 304000 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Dryer, Suspension Control > Component Information > Technical Service Bulletins > Page 9259 Air Dryer: Specifications Drier Hold Down Screw ......................................................................................................................................................... 7.6-10.4 Nm (68-88 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Dryer, Suspension Control > Component Information > Technical Service Bulletins > Page 9260 Air Dryer: Service and Repair REMOVAL 1. Remove the air compressor. 2. Remove the drier hold down screw. 3. Turn the drier clockwise and remove it from the air compressor. NOTE: Ensure that the O-ring at the drier nose does not fall off upon removal. INSTALLATION 1. Position drier into air compressor; turn counterclockwise to lock drier into place. NOTE: Ensure that the O-ring is on the drier nose upon installation for proper sealing. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Dryer, Suspension Control > Component Information > Technical Service Bulletins > Page 9261 2. Install the drier hold down screw. 3. Install the air compressor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Line, Suspension Control > Component Information > Technical Service Bulletins > Air Suspension - Repeat Compressor Drier Failures Air Line: Technical Service Bulletins Air Suspension - Repeat Compressor Drier Failures Article No. 03-9-2 05/12/03 ^ SUSPENSION - REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES ^ ELECTRICAL - REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES FORD: 1997-2002 EXPEDITION LINCOLN: 1998-2002 NAVIGATOR Article 03-7-9 is being republished in its entirety to update the Service Procedure. ISSUE Some 1997-2002 Expedition 4X4 and 1998-2002 Navigator 4X4 vehicles equipped with 4-wheel air suspension, may exhibit repeat air compressor drier failures. The drier cap may become detached from the drier body, or the drier body may be broken at the neck near the compressor head. This may be due to incomplete or incorrect system diagnosis that leads to replacement of only the original air suspension compressor, despite the fact that the compressor is not the root cause of the concern. Compressor failure in these instances is only a symptom of an underlying system problem. ACTION Refer to the service information contained in this TSB for information on proper diagnosis of system issues. Be sure to check the system for proper pneumatic function as described during service to ensure a robust repair. SERVICE INFORMATION Overview Proper pneumatic function can be tested by verifying that both the front AND the rear of the vehicle can be raised and lowered one inch using a scan tool, and by monitoring the height sensor PIDs for movement while the vehicle is in the service bay. If the vehicle does not raise and lower normally, check the solenoid valves and air lines for blockages and/or restrictions. Replace any blocked or restricted solenoids and air lines. ALWAYS check for proper pneumatic function before returning the vehicle back to the customer. NOTE DISCONNECTING AN AIR LINE THAT IS CONNECTED TO THE AIR COMPRESSOR CAN CAUSE PERSONAL INJURY OR DAMAGE TO COMPONENTS AS HIGH PRESSURE IS VENTED UNCONTROLLED. If diagnostics lead to compressor/dryer assembly replacement, use the following service procedure to insure complete and thorough service. 1. Using the New Generation STAR (NGS) tester, vent the compressor/drier assembly. 2. Using regulated shop air, blow out the air lines from the drier to the front fill solenoid valve and from the drier to the rear fill solenoid valve, before installing the new compressor assembly. 3. Replace the air suspension compressor assembly. Refer to Workshop Manual Section 204-05 for compressor installation instructions. 4. Replace the front fill solenoid. Refer to Workshop Manual Section 204-05 for replacement instructions. The front fill solenoid must be replaced because in these cases, it may have sustained damage from the drier desiccant or other contaminants. 5. Connect the New Generation STAR (NGS) tester to the vehicle while the vehicle is parked in the service bay with the engine running. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Line, Suspension Control > Component Information > Technical Service Bulletins > Air Suspension - Repeat Compressor Drier Failures > Page 9266 6. Install a pressure gauge capable of reading 400 PSI at the front air line (Figure 1). Using the scan tool, command the compressor ON. Check the output of the compressor on the gauge: a. If the compressor does not output at least 110 PSI within 30 seconds, replace the compressor again and retest. NOTE VERIFY THAT THE SUSPENSION RAISES PROPERLY. 7. Using the scan tool, command the front of the vehicle to raise up one inch. The front suspension should rise one inch in 25 seconds or less. a. If the compressor output is near 300 PSI, check4or air line or solenoid restrictions, repair as necessary and retest. Otherwise, proceed to Step 7b. NOTE SUSPENSION UPWARD MOVEMENT CAN BE VERIFIED BY MONITORING EITHER OF THE FRONT HEIGHT SENSOR PIDS, WHICH SHOULD DECREASE BY .35 TO .45 VOLTS. b. If the front of the vehicle DOES NOT raise, check the front pneumatic system for leaks, inoperable or blocked solenoid valves or pinched air lines. If an issue is found, repair as required and repeat Step 7 to verify proper operation. c. If no problem found, continue to Step 8. NOTE VERIFY THAT SUSPENSION PROPERLY. 8. If the front of the vehicle DOES raise, use the scan tool to command the front of the vehicle to lower one inch. The front suspension should lower one inch in 20 seconds or less. NOTE SUSPENSION DOWNWARD MOVEMENT CAN BE VERIFIED BY MONITORING EITHER OF THE FRONT HEIGHT SENSOR PIDS, WHICH SHOULD INCREASE BY .35 TO .45 VOLTS. a. If the front of the vehicle DOES NOT lower, check the front pneumatic system for leaks, inoperable or blocked solenoid valves, an inoperable vent solenoid, or pinched air lines. Repair air lines or replace solenoid valves as required. 9. Repeat Steps 7 and 8 for the rear. Command the rear of the vehicle, and monitor the rear height sensor PID. Voltages should increase when the vehicle is lowered, and decrease when the vehicle is raised. If the rear of the vehicle does not raise and lower as commanded, inspect the rear pneumatic system for leaks, inoperable or blocked solenoid valves, an inoperable vent solenoid, or pinched air lines, and repair as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Line, Suspension Control > Component Information > Technical Service Bulletins > Air Suspension - Repeat Compressor Drier Failures > Page 9267 10. If the vehicle raises and lowers normally in both the front and the rear, test drive the vehicle to confirm the repair. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-7-9 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 304000 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Line, Suspension Control > Component Information > Description and Operation > Four Wheel Air Suspension Air Line: Description and Operation Four Wheel Air Suspension There are six nylon air lines with quick connect air fittings in the vehicle that connect the air compressor, solenoids, air shocks, and air springs. One line connects the output of the compressor assembly to the front fill solenoid and the other line connect the output of compressor assembly to the rear fill solenoid. Another line connects the output of the rear fill solenoid to both the rear springs. The fifth air line in the front connects the output of the front fill solenoid to both the right front shock and the front gate solenoid. The last air line connects the output of the gate solenoids to the left shock. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Line, Suspension Control > Component Information > Description and Operation > Four Wheel Air Suspension > Page 9270 Air Line: Description and Operation Rear Air Suspension The air lines are connected at the compressor routed through the chassis of the vehicle to the rear air springs. There are two air lines on the air load leveling suspension system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Line, Suspension Control > Component Information > Service and Repair > Air Line Fluid Purge Air Line: Service and Repair Air Line Fluid Purge Front 1. Disconnect air line at compressor air drier that is connected to front fill solenoid inlet. NOTE: Perform this procedure if fluid (water and/or oil) is found in the front/rear air lines. Purge fluid from front/rear air lines and replace affected components. 2. Disconnect air line at inlet of front fill solenoid. 3. Connect shop air line to disconnected air line and blow out any fluid. 4. Reconnect air line. 5. Disconnect air line at compressor air drier that is connected to the front fill solenoid inlet. 6. Disconnect air line at RF shock. 7. Connect New Generation Star (NGS) tester to the vehicle. 8. Select the Active command mode for Expedition 4WAS turn on the following actuators: ^ FRNT-FILL (front fill solenoid) ON 9. Connect shop air line to disconnected air line and blow out any fluid. 10. Reconnect air line at RF shock absorber. 11. Disconnect air line at LF shock absorber. 12. Select the Active command mode for Expedition 4WAS turn on the following actuators: ^ FRNT_FILL (front fill solenoid) ON. ^ GATEVALVE (front gate solenoids) ON. 13. Connect shop air line to disconnected air line and blow out any fluid. 14. If oil was present in air lines, replace BOTH LF and RF shock absorbers. NOTE: Do not replace shock absorber for water. 15. Replace compressor air drier. 16. Reconnect air line to compressor drier. Rear 1. Disconnect air line at compressor air drier that is connected to rear fill solenoid inlet. 2. Disconnect air line at inlet of rear fill solenoid. 3. Connect shop air line to disconnected air line and blow out any fluid. 4. Reconnect air line. 5. Disconnect air line at compressor air drier that is connected to the rear fill solenoid inlet. 6. Disconnect air line at rear LH and RH air springs. 7. Connect New Generation Star (NGS) tester to the vehicle. 8. Select the Active command mode for Expedition 4WAS turn on the following actuators: ^ REAR_FILL (rear fill solenoid) ON. 9. Connect shop air line to disconnected air line and blow out any fluid. 10. Reconnect air line at the rear LH and RH air springs. 11. Replace compressor air drier. 12. Reconnect air line to compressor drier. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Line, Suspension Control > Component Information > Service and Repair > Air Line Fluid Purge > Page 9273 Air Line: Service and Repair Rear Air Suspension 1. Disconnect air line at compressor drier. NOTE: Perform this procedure if fluid (water and/or oil) is found in the rear air lines. Purge fluid from rear air lines and replace affected components. 2. Disconnect the rear LH and RH air lines from the air springs. 3. Connect shop air line to disconnected air line and blow any fluid out. 4. Reconnect the air lines at the RH and LH rear air springs. 5. Replace the air compressor drier. 6. Reconnect air line at compressor drier. 7. Ensure all air line fittings are sealed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Specifications Air Spring: Specifications Lower Bolt ............................................................................................................................................ ....................................... 76-103 Nm (56-76 ft. lbs.) Upper Nut .......................................................... ............................................................................................................................ 50-60 Nm (37-44 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Description and Operation > Four Wheel Air Suspension Air Spring: Description and Operation Four Wheel Air Suspension Rear Air Spring The 4WAS vehicles use a pneumatic spring in the rear. The pneumatic spring is essentially a column of gas confined in a container, utilizing the pressure of the gas as the force medium of the spring. The ability of the gas to compress provides the desired elasticity for the spring. The air suspension system regulates the pressure in each air spring by compressing and venting system air. Increasing air pressure (compressing) raises the vehicle; decreasing air pressure (venting) lowers the vehicle. Vehicle height is maintained by the addition and removal of air in each air spring through an integral solenoid assembled to the upper spring cap and energized through the control module command. The air spring assemblies are mounted between the axle spring seats and the frame upper spring seats. The air springs replace the conventional coil springs. Front Air Shock Absorbers There are different shock absorbers used for 4WAS air suspension system vehicles. 4WAS uses a conventional air shock. Enclosed in each shock absorber is an air spring. To replace a faulty shock absorber, replace the shock absorber as a unit. The air spring integrated into each air shock is capable of independently raising and lowering each corner of the vehicle based upon the pressure and volume of air supplied. The air suspension system regulates the pressure in each air shock by compressing and venting system air. Increasing air pressure (compressing) raises the vehicle and increases the total spring rate (spring effect of the air shock plus the front torsion bar) of the wheel being modified. Conversely, decreasing air pressure (venting) lowers the vehicle and effective spring rate. Vehicle height is then maintained by the addition and removal of air in each air shock. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Description and Operation > Four Wheel Air Suspension > Page 9279 Air Spring: Description and Operation Rear Air Suspension The RAS vehicles use a pneumatic spring in the rear. The pneumatic spring is essentially a column of gas confined in a container, utilizing the pressure of the gas as the force medium of the spring. The ability of the gas to compress provides the desired elasticity for the spring. The air suspension system regulates the pressure in each air spring by compressing and venting system air. Increasing air pressure (compressing) raises the rear of the vehicle decreasing air pressure (venting) lowers the rear of the vehicle. Vehicle height is maintained by the addition and removal of air in each air spring through an integral solenoid assembled to the upper spring cap and energized through the control module command. The air spring assemblies are mounted between the axle spring seats and the frame upper spring seats. The two air springs replace the conventional rear coil springs. The air springs store compressed air from the air compressor and raise and lower the rear end of the vehicle by compressing air in the air springs or releasing air from the air springs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Front Air Spring: Service and Repair Front REMOVAL 1. Bleed the air from the air suspension system. WARNING: DO NOT REMOVE AN AIR SHOCK UNDER ANY CIRCUMSTANCES WHEN THERE IS PRESSURE IN THE AIR SHOCK. DO NOT REMOVE ANY COMPONENTS SUPPORTING AN AIR SHOCK WITHOUT EITHER EXHAUSTING THE AIR OR PROVIDING SUPPORT FOR THE AIR SHOCK TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Raise and support the vehicle. 3. Remove the air shock lower nut and bolt. 4. Disconnect the air line. ^ Push the red ring in and hold firmly to remove the air line. WARNING: DISCONNECTING ANY AIR LINE THAT IS CONNECTED TO AN AIR SHOCK CAN CAUSE PERSONAL INJURY OR DAMAGE TO COMPONENTS AS HIGH PRESSURE AIR IS VENTED UNCONTROLLED. BEFORE DISCONNECTING AIR LINES CONNECTED TO AIR SHOCKS, USE NGS TESTER ACTIVE COMMAND VENT FNT TO RELIEVE ALL PRESSURE. CAUTION: For removal of LH front air shock absorber, always disconnect top of front height sensor from the upper frame bracket to prevent damage to the height sensor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Front > Page 9282 5. Remove the air shock upper nut and grommet. 6. Remove the air shock. INSTALLATION 1. To install, reverse the removal procedure. 2. Inflate the air shocks. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Front > Page 9283 Air Spring: Service and Repair Rear REMOVAL WARNING: DO NOT REMOVE AN AIR SPRING UNDER ANY CIRCUMSTANCES WHEN THERE IS PRESSURE IN THE AIR SPRING. DO NOT REMOVE ANY COMPONENTS SUPPORTING AN AIR SPRING WITHOUT EITHER EXHAUSTING THE AIR OR PROVIDING SUPPORT FOR THE AIR SPRING TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. 1. Bleed the air from the air suspension system. 2. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE FRONT, RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MANY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 3. Remove the rear air spring retainer. 4. Lift the bottom of the air spring off of the rear axle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Front > Page 9284 5. Disconnect the air line from the air spring. ^ Push the green ring in and hold finely to release and remove the air line. 6. Disconnect the solenoid electrical connector and remove the air spring. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When installing the air line into the air spring solenoid, a maximum of (3) mm (1/8 in) of white air line must be inserted for correct installation. 2. Inflate the air springs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > Customer Interest: > 05-26-18 > Dec > 05 > Suspension - Air Suspension Excessive Compressor Noise Compressor/Pump: Customer Interest Suspension - Air Suspension Excessive Compressor Noise TSB 05-26-18 12/31/05 AIR SUSPENSION COMPRESSOR NOISE FORD: 1997-2004 Expedition LINCOLN: 1998-2004 Navigator This article supersedes TSB 04-5-4 to update the Service Procedure. ISSUE Some 1997-2004 Expedition and 1998-2004 Navigator vehicles equipped with air suspension, may exhibit excessive noise from the air suspension compressor. ACTION To service, replace the compressor mounting bracket with a revised bracket. Order and install Noise Kit 4L1Z-5Z205-AA. Refer to the instruction sheets included in the Kit for installation procedures. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 052618A 1997-2004 1.0 Hr. Expedition/1998-2004 Navigator: Install Newly Designed Mounting Bracket And Isolators (Includes Time To Remove And Install Air Suspension Compressor) DEALER CODING CONDITION BASIC PART NO. CODE 5319 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > Customer Interest: > 99-2-2 > Feb > 99 > Air Suspension - Underhood Buzzing Noises Compressor/Pump: Customer Interest Air Suspension - Underhood Buzzing Noises Article No. 99-2-2 02/08/99 NOISE - "BUZZING" - UNDERHOOD WHEN AIR SUSPENSION IS IN OPERATION LIGHT TRUCK: 1997-99 EXPEDITION, F-25O LD 1998-99 NAVIGATOR This TSB article is being republished in its entirety to add 1998-99 model year vehicles. ISSUE An underhood "buzzing" noise may be heard during air suspension operation. This may be caused by: ^ the air pump lines being routed too close to the front end sheet metal ^ the wheelhouse inner may be sensitive to vibration input of air suspension compressor ACTION Wrap the air lines with foam tape and place mastic applique on sheet metal under air suspension compressor. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE FOAM TAPE MUST BE PLACED ON THE AIR LINES IN A LOCATION THAT WILL PREVENT THE AIR LINES FROM CONTACTING ANY SHEET METAL. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > Customer Interest: > 99-2-2 > Feb > 99 > Air Suspension - Underhood Buzzing Noises > Page 9297 1. Wrap the air lines with 12.7x101.6 mm (1/2x4") Foam Tape (Rotunda Squeak and Rattle Repair Kit PVC Foam Tape 164-R4901, or obtained locally) at the locations shown in Figure 1. Expedition/Navigator 4X2 and F-250 will need to be wrapped at A and B in Figure 1. Expedition/Navigator 4X4 will require tape at A, B, C, and D in Figure 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > Customer Interest: > 99-2-2 > Feb > 99 > Air Suspension - Underhood Buzzing Noises > Page 9298 2. If no groundouts are found, remove air compressor and place Mastic Appliques (XL1Z-3C244-AA and XL1Z-3C245-AA) on sheet metal under air suspension compressor at A and B in Figure 2. Place appliques as follows: a. Accurately place mastic onto sheet metal in a location that will not allow the cutouts for the mounting bolt to interfere with the mounting bracket. The air suspension compressor mounting bracket and the washer bottle reservoir should have complete contact with the sheet metal, and not the mastic, at the body mounting points. CAUTION BE SURE TO WEAR PROTECTIVE GLOVES WHEN CONFORMING THE MASTIC TO PREVENT FINGER BURNS. b. Using a heat gun, uniformly heat the mastic and apply pressure to form the mastic to the sheet metal surface. PART NUMBER PART NAME (Obtain Locally) 12.7x101.6 mm (1/2x4") Foam Tape XL1Z-3C244-AA Mastic Applique (1 Of 2) XL1z-3C245-AA Mastic Applique (2 Of 2) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-7-13 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > Customer Interest: > 99-2-2 > Feb > 99 > Air Suspension - Underhood Buzzing Noises > Page 9299 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 990202A Apply Foam Tape To 0.5 Hr. Contact Areas - 4X2 And 4X4 Models 990202B Apply Mastic Applique 1.0 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 3B484 43 OASIS CODES: 304000, 702000, 702100, 703000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor/Pump: > 05-26-18 > Dec > 05 > Suspension - Air Suspension Excessive Compressor Noise Compressor/Pump: All Technical Service Bulletins Suspension - Air Suspension Excessive Compressor Noise TSB 05-26-18 12/31/05 AIR SUSPENSION COMPRESSOR NOISE FORD: 1997-2004 Expedition LINCOLN: 1998-2004 Navigator This article supersedes TSB 04-5-4 to update the Service Procedure. ISSUE Some 1997-2004 Expedition and 1998-2004 Navigator vehicles equipped with air suspension, may exhibit excessive noise from the air suspension compressor. ACTION To service, replace the compressor mounting bracket with a revised bracket. Order and install Noise Kit 4L1Z-5Z205-AA. Refer to the instruction sheets included in the Kit for installation procedures. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 052618A 1997-2004 1.0 Hr. Expedition/1998-2004 Navigator: Install Newly Designed Mounting Bracket And Isolators (Includes Time To Remove And Install Air Suspension Compressor) DEALER CODING CONDITION BASIC PART NO. CODE 5319 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor/Pump: > 03-9-2 > May > 03 > Air Suspension - Repeat Compressor Drier Failures Compressor/Pump: All Technical Service Bulletins Air Suspension - Repeat Compressor Drier Failures Article No. 03-9-2 05/12/03 ^ SUSPENSION - REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES ^ ELECTRICAL - REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES FORD: 1997-2002 EXPEDITION LINCOLN: 1998-2002 NAVIGATOR Article 03-7-9 is being republished in its entirety to update the Service Procedure. ISSUE Some 1997-2002 Expedition 4X4 and 1998-2002 Navigator 4X4 vehicles equipped with 4-wheel air suspension, may exhibit repeat air compressor drier failures. The drier cap may become detached from the drier body, or the drier body may be broken at the neck near the compressor head. This may be due to incomplete or incorrect system diagnosis that leads to replacement of only the original air suspension compressor, despite the fact that the compressor is not the root cause of the concern. Compressor failure in these instances is only a symptom of an underlying system problem. ACTION Refer to the service information contained in this TSB for information on proper diagnosis of system issues. Be sure to check the system for proper pneumatic function as described during service to ensure a robust repair. SERVICE INFORMATION Overview Proper pneumatic function can be tested by verifying that both the front AND the rear of the vehicle can be raised and lowered one inch using a scan tool, and by monitoring the height sensor PIDs for movement while the vehicle is in the service bay. If the vehicle does not raise and lower normally, check the solenoid valves and air lines for blockages and/or restrictions. Replace any blocked or restricted solenoids and air lines. ALWAYS check for proper pneumatic function before returning the vehicle back to the customer. NOTE DISCONNECTING AN AIR LINE THAT IS CONNECTED TO THE AIR COMPRESSOR CAN CAUSE PERSONAL INJURY OR DAMAGE TO COMPONENTS AS HIGH PRESSURE IS VENTED UNCONTROLLED. If diagnostics lead to compressor/dryer assembly replacement, use the following service procedure to insure complete and thorough service. 1. Using the New Generation STAR (NGS) tester, vent the compressor/drier assembly. 2. Using regulated shop air, blow out the air lines from the drier to the front fill solenoid valve and from the drier to the rear fill solenoid valve, before installing the new compressor assembly. 3. Replace the air suspension compressor assembly. Refer to Workshop Manual Section 204-05 for compressor installation instructions. 4. Replace the front fill solenoid. Refer to Workshop Manual Section 204-05 for replacement instructions. The front fill solenoid must be replaced because in these cases, it may have sustained damage from the drier desiccant or other contaminants. 5. Connect the New Generation STAR (NGS) tester to the vehicle while the vehicle is parked in the service bay with the engine running. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor/Pump: > 03-9-2 > May > 03 > Air Suspension - Repeat Compressor Drier Failures > Page 9309 6. Install a pressure gauge capable of reading 400 PSI at the front air line (Figure 1). Using the scan tool, command the compressor ON. Check the output of the compressor on the gauge: a. If the compressor does not output at least 110 PSI within 30 seconds, replace the compressor again and retest. NOTE VERIFY THAT THE SUSPENSION RAISES PROPERLY. 7. Using the scan tool, command the front of the vehicle to raise up one inch. The front suspension should rise one inch in 25 seconds or less. a. If the compressor output is near 300 PSI, check4or air line or solenoid restrictions, repair as necessary and retest. Otherwise, proceed to Step 7b. NOTE SUSPENSION UPWARD MOVEMENT CAN BE VERIFIED BY MONITORING EITHER OF THE FRONT HEIGHT SENSOR PIDS, WHICH SHOULD DECREASE BY .35 TO .45 VOLTS. b. If the front of the vehicle DOES NOT raise, check the front pneumatic system for leaks, inoperable or blocked solenoid valves or pinched air lines. If an issue is found, repair as required and repeat Step 7 to verify proper operation. c. If no problem found, continue to Step 8. NOTE VERIFY THAT SUSPENSION PROPERLY. 8. If the front of the vehicle DOES raise, use the scan tool to command the front of the vehicle to lower one inch. The front suspension should lower one inch in 20 seconds or less. NOTE SUSPENSION DOWNWARD MOVEMENT CAN BE VERIFIED BY MONITORING EITHER OF THE FRONT HEIGHT SENSOR PIDS, WHICH SHOULD INCREASE BY .35 TO .45 VOLTS. a. If the front of the vehicle DOES NOT lower, check the front pneumatic system for leaks, inoperable or blocked solenoid valves, an inoperable vent solenoid, or pinched air lines. Repair air lines or replace solenoid valves as required. 9. Repeat Steps 7 and 8 for the rear. Command the rear of the vehicle, and monitor the rear height sensor PID. Voltages should increase when the vehicle is lowered, and decrease when the vehicle is raised. If the rear of the vehicle does not raise and lower as commanded, inspect the rear pneumatic system for leaks, inoperable or blocked solenoid valves, an inoperable vent solenoid, or pinched air lines, and repair as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor/Pump: > 03-9-2 > May > 03 > Air Suspension - Repeat Compressor Drier Failures > Page 9310 10. If the vehicle raises and lowers normally in both the front and the rear, test drive the vehicle to confirm the repair. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-7-9 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 304000 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor/Pump: > 99-2-2 > Feb > 99 > Air Suspension - Underhood Buzzing Noises Compressor/Pump: All Technical Service Bulletins Air Suspension - Underhood Buzzing Noises Article No. 99-2-2 02/08/99 NOISE - "BUZZING" - UNDERHOOD WHEN AIR SUSPENSION IS IN OPERATION LIGHT TRUCK: 1997-99 EXPEDITION, F-25O LD 1998-99 NAVIGATOR This TSB article is being republished in its entirety to add 1998-99 model year vehicles. ISSUE An underhood "buzzing" noise may be heard during air suspension operation. This may be caused by: ^ the air pump lines being routed too close to the front end sheet metal ^ the wheelhouse inner may be sensitive to vibration input of air suspension compressor ACTION Wrap the air lines with foam tape and place mastic applique on sheet metal under air suspension compressor. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE FOAM TAPE MUST BE PLACED ON THE AIR LINES IN A LOCATION THAT WILL PREVENT THE AIR LINES FROM CONTACTING ANY SHEET METAL. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor/Pump: > 99-2-2 > Feb > 99 > Air Suspension - Underhood Buzzing Noises > Page 9315 1. Wrap the air lines with 12.7x101.6 mm (1/2x4") Foam Tape (Rotunda Squeak and Rattle Repair Kit PVC Foam Tape 164-R4901, or obtained locally) at the locations shown in Figure 1. Expedition/Navigator 4X2 and F-250 will need to be wrapped at A and B in Figure 1. Expedition/Navigator 4X4 will require tape at A, B, C, and D in Figure 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor/Pump: > 99-2-2 > Feb > 99 > Air Suspension - Underhood Buzzing Noises > Page 9316 2. If no groundouts are found, remove air compressor and place Mastic Appliques (XL1Z-3C244-AA and XL1Z-3C245-AA) on sheet metal under air suspension compressor at A and B in Figure 2. Place appliques as follows: a. Accurately place mastic onto sheet metal in a location that will not allow the cutouts for the mounting bolt to interfere with the mounting bracket. The air suspension compressor mounting bracket and the washer bottle reservoir should have complete contact with the sheet metal, and not the mastic, at the body mounting points. CAUTION BE SURE TO WEAR PROTECTIVE GLOVES WHEN CONFORMING THE MASTIC TO PREVENT FINGER BURNS. b. Using a heat gun, uniformly heat the mastic and apply pressure to form the mastic to the sheet metal surface. PART NUMBER PART NAME (Obtain Locally) 12.7x101.6 mm (1/2x4") Foam Tape XL1Z-3C244-AA Mastic Applique (1 Of 2) XL1z-3C245-AA Mastic Applique (2 Of 2) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-7-13 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor/Pump: > 99-2-2 > Feb > 99 > Air Suspension - Underhood Buzzing Noises > Page 9317 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 990202A Apply Foam Tape To 0.5 Hr. Contact Areas - 4X2 And 4X4 Models 990202B Apply Mastic Applique 1.0 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 3B484 43 OASIS CODES: 304000, 702000, 702100, 703000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compressor/Pump: > 03-9-2 > May > 03 > Air Suspension - Repeat Compressor Drier Failures Compressor/Pump: All Technical Service Bulletins Air Suspension - Repeat Compressor Drier Failures Article No. 03-9-2 05/12/03 ^ SUSPENSION - REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES ^ ELECTRICAL - REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES FORD: 1997-2002 EXPEDITION LINCOLN: 1998-2002 NAVIGATOR Article 03-7-9 is being republished in its entirety to update the Service Procedure. ISSUE Some 1997-2002 Expedition 4X4 and 1998-2002 Navigator 4X4 vehicles equipped with 4-wheel air suspension, may exhibit repeat air compressor drier failures. The drier cap may become detached from the drier body, or the drier body may be broken at the neck near the compressor head. This may be due to incomplete or incorrect system diagnosis that leads to replacement of only the original air suspension compressor, despite the fact that the compressor is not the root cause of the concern. Compressor failure in these instances is only a symptom of an underlying system problem. ACTION Refer to the service information contained in this TSB for information on proper diagnosis of system issues. Be sure to check the system for proper pneumatic function as described during service to ensure a robust repair. SERVICE INFORMATION Overview Proper pneumatic function can be tested by verifying that both the front AND the rear of the vehicle can be raised and lowered one inch using a scan tool, and by monitoring the height sensor PIDs for movement while the vehicle is in the service bay. If the vehicle does not raise and lower normally, check the solenoid valves and air lines for blockages and/or restrictions. Replace any blocked or restricted solenoids and air lines. ALWAYS check for proper pneumatic function before returning the vehicle back to the customer. NOTE DISCONNECTING AN AIR LINE THAT IS CONNECTED TO THE AIR COMPRESSOR CAN CAUSE PERSONAL INJURY OR DAMAGE TO COMPONENTS AS HIGH PRESSURE IS VENTED UNCONTROLLED. If diagnostics lead to compressor/dryer assembly replacement, use the following service procedure to insure complete and thorough service. 1. Using the New Generation STAR (NGS) tester, vent the compressor/drier assembly. 2. Using regulated shop air, blow out the air lines from the drier to the front fill solenoid valve and from the drier to the rear fill solenoid valve, before installing the new compressor assembly. 3. Replace the air suspension compressor assembly. Refer to Workshop Manual Section 204-05 for compressor installation instructions. 4. Replace the front fill solenoid. Refer to Workshop Manual Section 204-05 for replacement instructions. The front fill solenoid must be replaced because in these cases, it may have sustained damage from the drier desiccant or other contaminants. 5. Connect the New Generation STAR (NGS) tester to the vehicle while the vehicle is parked in the service bay with the engine running. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compressor/Pump: > 03-9-2 > May > 03 > Air Suspension - Repeat Compressor Drier Failures > Page 9323 6. Install a pressure gauge capable of reading 400 PSI at the front air line (Figure 1). Using the scan tool, command the compressor ON. Check the output of the compressor on the gauge: a. If the compressor does not output at least 110 PSI within 30 seconds, replace the compressor again and retest. NOTE VERIFY THAT THE SUSPENSION RAISES PROPERLY. 7. Using the scan tool, command the front of the vehicle to raise up one inch. The front suspension should rise one inch in 25 seconds or less. a. If the compressor output is near 300 PSI, check4or air line or solenoid restrictions, repair as necessary and retest. Otherwise, proceed to Step 7b. NOTE SUSPENSION UPWARD MOVEMENT CAN BE VERIFIED BY MONITORING EITHER OF THE FRONT HEIGHT SENSOR PIDS, WHICH SHOULD DECREASE BY .35 TO .45 VOLTS. b. If the front of the vehicle DOES NOT raise, check the front pneumatic system for leaks, inoperable or blocked solenoid valves or pinched air lines. If an issue is found, repair as required and repeat Step 7 to verify proper operation. c. If no problem found, continue to Step 8. NOTE VERIFY THAT SUSPENSION PROPERLY. 8. If the front of the vehicle DOES raise, use the scan tool to command the front of the vehicle to lower one inch. The front suspension should lower one inch in 20 seconds or less. NOTE SUSPENSION DOWNWARD MOVEMENT CAN BE VERIFIED BY MONITORING EITHER OF THE FRONT HEIGHT SENSOR PIDS, WHICH SHOULD INCREASE BY .35 TO .45 VOLTS. a. If the front of the vehicle DOES NOT lower, check the front pneumatic system for leaks, inoperable or blocked solenoid valves, an inoperable vent solenoid, or pinched air lines. Repair air lines or replace solenoid valves as required. 9. Repeat Steps 7 and 8 for the rear. Command the rear of the vehicle, and monitor the rear height sensor PID. Voltages should increase when the vehicle is lowered, and decrease when the vehicle is raised. If the rear of the vehicle does not raise and lower as commanded, inspect the rear pneumatic system for leaks, inoperable or blocked solenoid valves, an inoperable vent solenoid, or pinched air lines, and repair as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compressor/Pump: > 03-9-2 > May > 03 > Air Suspension - Repeat Compressor Drier Failures > Page 9324 10. If the vehicle raises and lowers normally in both the front and the rear, test drive the vehicle to confirm the repair. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-7-9 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 304000 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > Page 9325 Compressor/Pump: Specifications Air Compressor Bracket Bolts ................................................................................................................................................ 7.6-10.4 Nm (68-88 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > Page 9326 Compressor/Pump: Description and Operation The air compressor assembly: ^ Consists of the compressor and vent solenoid; neither are replaceable as individual items. ^ Is mounted in the engine compartment between the washer fluid bottle and headlamp (RH front corner). ^ Is a single cylinder electric motor driven unit that provides pressurized air as required. ^ Is powered by a solid state relay, controlled by the control module. ^ Passes pressurized air through the compressor air drier that contains silica gel (a drying agent). Moisture is then removed from the compressor air drier when vented air passes out of the system during vent operation. ^ The compressor air drier may be replaced separately. ^ Incorporates a silencer for noise reduction; may be replaced separately. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Service and Repair > Four Wheel Air Suspension Compressor/Pump: Service and Repair Four Wheel Air Suspension REMOVAL 1. Remove the windshield reservoir. WARNING: BEFORE REPAIRING ANY AIR SUSPENSION COMPONENTS, DISCONNECT THE POWER TO THE SYSTEM BY TURNING OFF THE SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. 2. Disconnect the air lines from the air compressor. (1) Depress the red plastic retaining rings and hold firmly while pulling out on the air lines. (2) Disconnect the air lines. 3. Disconnect the air compressor electrical connector. 4. Remove the air compressor bracket bolts and remove the air compressor and drier assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Service and Repair > Four Wheel Air Suspension > Page 9329 INSTALLATION 1. To install, reverse the removal procedure. NOTE: When reinstalling air lines into compressor drier a maximum of 3 mm (1/8 in) of visible white air line must be installed for correct installation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Service and Repair > Four Wheel Air Suspension > Page 9330 Compressor/Pump: Service and Repair Rear Air Suspension REMOVAL 1. Remove the windshield washer reservoir. WARNING: BEFORE SERVICING ANY AIR SUSPENSION COMPONENTS, DISCONNECT THE POWER TO THE SYSTEM BY TURNING OF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. 2. Disconnect the air line from the air compressor. (1) Depress the red plastic retaining ring and hold firmly while pulling out on the air line. (2) Disconnect the air line. 3. Disconnect the air compressor electrical connector. 4. Remove the air compressor bracket bolts and remove the air compressor and drier assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Service and Repair > Four Wheel Air Suspension > Page 9331 INSTALLATION 1. To install, reverse the removal procedure. NOTE: When installing air line into drier, a maximum of 3 mm (1/8 in) of visible white air line must be inserted for correct installation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump Relay, Suspension Control > Component Information > Locations Compressor/Pump Relay: Locations Engine View The Air Suspension Compressor Relay is located near the right headlamp. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 9335 Compressor/Pump Relay: Description and Operation A Solid State Relay is used in the air suspension system for compressor control. The relay incorporates a custom power MOSFET and ceramic hybrid circuitry. The relay switches high current loads in response to low power signals and is controlled by the logic of the control module. The compressor relay is energized by the control module to have high current flow from the battery to the compressor motor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Diagnostic Connector, Suspension > Component Information > Description and Operation Diagnostic Connector: Description and Operation The air suspension diagnostic connector is used to aid the technician in diagnosing the air suspension system. It is also used to vent the system of compressed air when air suspension system components need to be repaired or replaced. The air suspension diagnostic connector is located under steering column. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Technical Service Bulletins > Air Suspension - Repeat Compressor Drier Failures Level Control Solenoid Valve: Technical Service Bulletins Air Suspension - Repeat Compressor Drier Failures Article No. 03-9-2 05/12/03 ^ SUSPENSION - REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES ^ ELECTRICAL - REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES FORD: 1997-2002 EXPEDITION LINCOLN: 1998-2002 NAVIGATOR Article 03-7-9 is being republished in its entirety to update the Service Procedure. ISSUE Some 1997-2002 Expedition 4X4 and 1998-2002 Navigator 4X4 vehicles equipped with 4-wheel air suspension, may exhibit repeat air compressor drier failures. The drier cap may become detached from the drier body, or the drier body may be broken at the neck near the compressor head. This may be due to incomplete or incorrect system diagnosis that leads to replacement of only the original air suspension compressor, despite the fact that the compressor is not the root cause of the concern. Compressor failure in these instances is only a symptom of an underlying system problem. ACTION Refer to the service information contained in this TSB for information on proper diagnosis of system issues. Be sure to check the system for proper pneumatic function as described during service to ensure a robust repair. SERVICE INFORMATION Overview Proper pneumatic function can be tested by verifying that both the front AND the rear of the vehicle can be raised and lowered one inch using a scan tool, and by monitoring the height sensor PIDs for movement while the vehicle is in the service bay. If the vehicle does not raise and lower normally, check the solenoid valves and air lines for blockages and/or restrictions. Replace any blocked or restricted solenoids and air lines. ALWAYS check for proper pneumatic function before returning the vehicle back to the customer. NOTE DISCONNECTING AN AIR LINE THAT IS CONNECTED TO THE AIR COMPRESSOR CAN CAUSE PERSONAL INJURY OR DAMAGE TO COMPONENTS AS HIGH PRESSURE IS VENTED UNCONTROLLED. If diagnostics lead to compressor/dryer assembly replacement, use the following service procedure to insure complete and thorough service. 1. Using the New Generation STAR (NGS) tester, vent the compressor/drier assembly. 2. Using regulated shop air, blow out the air lines from the drier to the front fill solenoid valve and from the drier to the rear fill solenoid valve, before installing the new compressor assembly. 3. Replace the air suspension compressor assembly. Refer to Workshop Manual Section 204-05 for compressor installation instructions. 4. Replace the front fill solenoid. Refer to Workshop Manual Section 204-05 for replacement instructions. The front fill solenoid must be replaced because in these cases, it may have sustained damage from the drier desiccant or other contaminants. 5. Connect the New Generation STAR (NGS) tester to the vehicle while the vehicle is parked in the service bay with the engine running. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Technical Service Bulletins > Air Suspension - Repeat Compressor Drier Failures > Page 9343 6. Install a pressure gauge capable of reading 400 PSI at the front air line (Figure 1). Using the scan tool, command the compressor ON. Check the output of the compressor on the gauge: a. If the compressor does not output at least 110 PSI within 30 seconds, replace the compressor again and retest. NOTE VERIFY THAT THE SUSPENSION RAISES PROPERLY. 7. Using the scan tool, command the front of the vehicle to raise up one inch. The front suspension should rise one inch in 25 seconds or less. a. If the compressor output is near 300 PSI, check4or air line or solenoid restrictions, repair as necessary and retest. Otherwise, proceed to Step 7b. NOTE SUSPENSION UPWARD MOVEMENT CAN BE VERIFIED BY MONITORING EITHER OF THE FRONT HEIGHT SENSOR PIDS, WHICH SHOULD DECREASE BY .35 TO .45 VOLTS. b. If the front of the vehicle DOES NOT raise, check the front pneumatic system for leaks, inoperable or blocked solenoid valves or pinched air lines. If an issue is found, repair as required and repeat Step 7 to verify proper operation. c. If no problem found, continue to Step 8. NOTE VERIFY THAT SUSPENSION PROPERLY. 8. If the front of the vehicle DOES raise, use the scan tool to command the front of the vehicle to lower one inch. The front suspension should lower one inch in 20 seconds or less. NOTE SUSPENSION DOWNWARD MOVEMENT CAN BE VERIFIED BY MONITORING EITHER OF THE FRONT HEIGHT SENSOR PIDS, WHICH SHOULD INCREASE BY .35 TO .45 VOLTS. a. If the front of the vehicle DOES NOT lower, check the front pneumatic system for leaks, inoperable or blocked solenoid valves, an inoperable vent solenoid, or pinched air lines. Repair air lines or replace solenoid valves as required. 9. Repeat Steps 7 and 8 for the rear. Command the rear of the vehicle, and monitor the rear height sensor PID. Voltages should increase when the vehicle is lowered, and decrease when the vehicle is raised. If the rear of the vehicle does not raise and lower as commanded, inspect the rear pneumatic system for leaks, inoperable or blocked solenoid valves, an inoperable vent solenoid, or pinched air lines, and repair as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Technical Service Bulletins > Air Suspension - Repeat Compressor Drier Failures > Page 9344 10. If the vehicle raises and lowers normally in both the front and the rear, test drive the vehicle to confirm the repair. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-7-9 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 304000 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Description and Operation > Electronic Level Control Solenoid Valve Level Control Solenoid Valve: Description and Operation Electronic Level Control Solenoid Valve Four Wheel Air Suspension WARNING: NEVER ROTATE AN AIR SPRING SOLENOID VALVE TO THE RELEASE SLOT IN THE END CAP FITTING UNTIL ALL PRESSURIZED AIR HAS ESCAPED FROM THE SPRING TO PREVENT DAMAGE OR INJURY. The air spring solenoid valve: ^ Allows air to enter and exit the air spring during leveling operations. ^ Is electrically operated and controlled by the control module. ^ Is only replaced as a unit. Rear Air Suspension WARNING: NEVER ROTATE AN AIR SPRING SOLENOID VALVE TO THE RELEASE SLOT IN THE END CAP FITTING UNTIL ALL PRESSURIZED AIR HAS ESCAPED FROM THE SPRING TO PREVENT DAMAGE OR INJURY. The air spring solenoid valve: ^ allows air to enter and exit the air spring during leveling operations. ^ is electrically operated and controlled by the control module. ^ is only replaceable as one part. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Description and Operation > Electronic Level Control Solenoid Valve > Page 9347 Level Control Solenoid Valve: Description and Operation Inflator Solenoid, Level Control Front Fill Solenoid The front fill solenoid connects the output of the compressor assembly to the two front air shocks. When energized along with the front gate solenoid, air pressure to the front axle can be modified, affecting its height relative to the body. Front Gate Solenoid The front gate solenoid provides pneumatic isolation of the left and right sides of the vehicle. The separation is necessary to eliminate the transfer of air from left to right front air shocks during roll conditions. When the solenoids are off (closed) the left and right air shocks are separated, allowing a pressure differential to be generated. In a turn, the increased pressure in the two outermost air shocks raises the two outer wheel spring rates, decreasing vehicle roll. Conversely, opening (energizing) the gate solenoid on smooth driving surfaces connects the left and right air shocks. This forces left and right side air pressures to be the same. Also, allowing the transfer of air reduces the resistance to vertical wheel movement, resulting in a softer ride. Rear Fill Solenoid The rear fill solenoid connects the output of the compressor assembly to the two rear air shocks. When energized along with the two integrated rear solenoids, air pressure to the rear axle can be modified, affecting its height relative to the body. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Description and Operation > Electronic Level Control Solenoid Valve > Page 9348 Level Control Solenoid Valve: Description and Operation Vent Solenoid (Level Control) The vent solenoid valve: ^ Allows air to escape from the system during venting actions. ^ Is located in the air compressor cylinder head. ^ Shares a common electrical connector with the air compressor motor. ^ Is enclosed in the cylinder head casting, which forms an integral valve housing that allows the valve tip to enter the pressurized side of the system. ^ Has an O-ring seal that prevents air leakage past the valve tip. ^ Opens when the control module determines lowering is required. ^ Provides an escape route for pressurized air that opens when system pressures exceed safe operating levels. ^ Is not a replaceable item. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Electronic Level Control Solenoid Valve Level Control Solenoid Valve: Service and Repair Electronic Level Control Solenoid Valve Four Wheel Air Suspension REMOVAL 1. Remove the air spring assembly. 2. Remove the metal retaining clip from the air spring solenoid. CAUTION: Remove any dirt or other debris from the air spring assembly prior to removing to air spring solenoid from the air spring assembly. 3. Twist air spring solenoid and remove. NOTE: Inspect solenoid O-rings and replace as necessary. INSTALLATION 1. To install, reverse the removal procedure. Rear Air Suspension REMOVAL 1. Remove the air spring assembly. 2. Remove the metal retaining clip from the ail spring solenoid. CAUTION: Remove any dirt or other debris from the air spring assembly prior to removing to air spring solenoid from the air spring assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Electronic Level Control Solenoid Valve > Page 9351 3. Twist air spring solenoid and remove. NOTE: Inspect solenoid O-rings and replace as necessary. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Electronic Level Control Solenoid Valve > Page 9352 Level Control Solenoid Valve: Service and Repair Inflator Solenoid, Level Control REMOVAL 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Push in the red ring and hold thinly to remove the air lines. WARNING: DISCONNECTING ANY AIR LINE THAT IS CONNECTED TO AN AIR SHOCK CAN CAUSE PERSONAL INJURY OR DAMAGE TO COMPONENTS AS HIGH PRESSURE AIR IS VENTED UNCONTROLLED. BEFORE DISCONNECTING AIR LINES CONNECTED TO AIR SHOCKS, USE NGS TESTER ACTIVE COMMAND VENT FNT TO RELIEVE ALL PRESSURE. 3. Disconnect the electrical connector. 4. Pry solenoid from the frame. NOTE: Rear fill solenoid shown, front gate solenoid and front fill solenoid similar. INSTALLATION 1. To install reverse removal procedure. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. When installing air line into solenoid a maximum of 3 mm (1/8 in) of white air line must be installed for correct installation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Locations > Front Ride Height Sensor: Locations Front Body View The Front Height Sensor is located behind left running broad. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Locations > Front > Page 9357 Ride Height Sensor: Locations Rear Body View The Rear Height Sensor is located at rear floor panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Description and Operation > Four Wheel Air Suspension Ride Height Sensor: Description and Operation Four Wheel Air Suspension Two height sensors are mounted on the vehicle. The sensors send a voltage signal to the control module. The output ranges from approximately 4.75 volts at minimum height (when the vehicle is low or in full jounce), to 0.25 volts at maximum height (when the vehicle is high or in full rebound). The sensors have a useable range of 80 mm (3 in) compared to total suspension travel of 200-250 mm (8-10 in) at the wheel. Therefore, the sensors are mounted to the suspension at a point where full suspension travel at the wheel is relative to 80 mm (3 in) of travel at the height sensor. The front height sensor upper socket is attached to the bracket to the frame at the upper control arm mounting area and the lower height sensor socket is attached to the upper control arm bracket. The rear height sensor is attached between the No. 5 frame crossmember (upper socket) and the panhard rod (lower socket). Replace a sensor as a unit. When the height sensor gets shorter the vehicle is lowered and this will cause the air compressor to turn on and pump compressed air to the system. When the sensor gets longer the vehicle is being raised and this will cause the air to be vented from the system to lower the vehicle to its trim height level. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Description and Operation > Four Wheel Air Suspension > Page 9360 Ride Height Sensor: Description and Operation Rear Air Suspension When the height sensor gets shorter the rear of the vehicle is lowered and this will cause the air compressor to turn on and pump compressed air to the air springs. When the sensor gets longer the rear of the vehicle is being raised and this will cause the air to be vented from the air springs to lower the vehicle back to its trim height level. One height sensor is mounted on the vehicle. The sensor sends a voltage signal to the control module. The output ranges from approximately 4.75 volts at minimum height (when the vehicle is low or in full jounce), to 0.25 volts at maximum height (when the vehicle is high or in full rebound). The sensor has a useable range of 80 mm (3 in) compared to total suspension travel of 200-250 mm (8 to 10 in) at the wheel. Therefore, the sensor is mounted to the suspension at a point where full rear suspension travel at the wheel is relative to 80 mm of travel at the height sensor. The rear height sensor is attached between the No. 5 frame crossmember (upper socket) and the panhard rod (lower socket). Replace the sensor as a unit. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Adjustments > Inflate and Deflate the Air Suspension System Ride Height Sensor: Adjustments Inflate and Deflate the Air Suspension System 1. Turn the ignition to the run position. WARNING: DO NOT REMOVE AN AIR SPRING UNDER ANY CIRCUMSTANCES WHEN THERE IS PRESSURE IN THE AIR SPRING. DO NOT REMOVE ANY COMPONENTS SUPPORTING AN AIR SPRING WITHOUT EITHER EXHAUSTING THE AIR OR PROVIDING SUPPORT FOR THE AIR SPRING TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. 2. Connect NGS tester to vehicle. 3. Select 1997 4.6L/5.4L Expedition 4WAS module. 4. Select "Air Suspension Control Mode" under "Active Command Modes" menu. (1) Select "VENT REAR" to deflate rear air springs. (2) Select "LIFT REAR" to inflate rear air springs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Adjustments > Inflate and Deflate the Air Suspension System > Page 9363 Ride Height Sensor: Adjustments Rear Height Resetting Procedure 1. Turn ignition key on. 2. Connect NGS tester to the vehicle. 3. Select 1997 4.6L/5.4L Expedition-4WAS module. 4. Measure vehicle rear height (driver side) from the bottom of the frame to the rear jounce bumper bolt rear side of head base. 5. By using NGS tester "active command modes", adjust rear height to 146.8 +/- 2 mm by moving rear of the vehicle down "VENT REAR" or moving rear of the vehicle up "LIFT REAR." 6. Monitor on the right side of the NGS screen rear height sensor voltage. 7. Loosen the ball stud nut on rear height sensor bracket on track bar and adjust by moving with height sensor up or down until rear height sensor voltage is 2.61 +/- 0.03 volt. 8. Tighten nut to specifications. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Adjustments > Page 9364 Ride Height Sensor: Service and Repair REMOVAL 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO S O MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Remove the air suspension height sensor. (1) Disconnect electrical connector. (2) Depress the metal retaining tabs and remove the air suspension height sensor from the ball studs. NOTE: The air suspension height sensor has a plastic harness retainer to suspension that must be unclipped prior to removal. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Technical Service Bulletin # 01-12-8 Date: 010625 Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Article No. 01-12-8 06/25/01 ^ SUSPENSION - AIR SUSPENSION - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE ^ ELECTRICAL - LAMP - AIR SUSPENSION LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE FORD: 1997-2001 EXPEDITION LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit a check suspension lamp ON with Diagnostic Trouble Codes (DTC's) B2140 or C2140 even after the Air Suspension switch in the upper RH kick panel has been turned on. This may occur at pre-delivery, following suspension service, or after Air Suspension module replacement. This may be caused by the ride height calibration. ACTION Adjust and/or recalibrate ride height as necessary using the NGS (New Generation Star) Tester. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011208A Recalibrate Ride Height 0.2 Hr. For Rear Air Suspension (R.A.S.) 4X2 Vehicles Only 011208B Recalibrate Ride Height 0.5 Hr. For 4 Wheel Air Suspension (4W.A.S.) (Includes Time To Adjust Torsion Bars 4X4 Vehicles Only) DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000, 390000 Service Procedure NOTE DURING PDI (PRE-DELIVERY INSPECTION) IF "CK SUSP" LIGHT IS ON, PRIOR TO SENDING TO SERVICE, VERIFY SWITCH IN UPPER RIGHT KICK PANEL IS ON. THIS SWITCH IS TURNED OFF DURING VEHICLE SHIPMENT TO PREVENT MODULE FROM SEEKING TRIM HEIGHT WHILE SECURED DOWN FOR TRANSPORT. NOTE AN INADVERTENT B2140 OR C2140 MAY RESULT IF A PARAMETER RESET (CLEAR RIDE HEIGHT) IS SELECTED UNDER NGS ACTIVE COMMANDS, THEN CANCELLED OUT. NOTE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 9373 THE AIR SUSPENSION CONTROL MODULE PART NUMBER IS INTERCHANGEABLE BETWEEN THE REAR AIR SUSPENSION (RAS) AND 4-WHEEL AIR SUSPENSION (4WAS) SYSTEMS, BUT ONCE THE MODULE IS INSTALLED, THE VEHICLE WILL THEN DETERMINE WHETHER VEHICLE IS 4X2 (RAS) OR 4X4 (4WAS) BASED ON VEHICLE HARNESS INPUTS. NOTE MODULES ARE PRE-PROGRAMMED TO SEEK 2.66 VOLTS + 1.02 VOLTS FROM REAR HEIGHT SENSOR (RHGSTEN PARAMETER IDENTIFIER OR PID) AT TRIM HEIGHT. HOWEVER, A NEW OR SWAPPED MODULE REQUIRES CALIBRATION PER STEPS BELOW TO CLEAR A 2140 (INITIALIZATION FAILURE) CODE. NOTE PERFORM 4WAS-AIR SUSP/EVO (ELECTRONIC VARIABLE ORIFICE STEERING) SELF TEST AND MAKE NECESSARY REPAIRS FOR ANY OTHER AIR SUSPENSION DTC'S THAT ARE PRESENT BEFORE ADDRESSING B2140/C2140. WARNING WARNING: BEFORE REPLACING ANY AIR SUSPENSION COMPONENTS, HOISTING, JACKING, OR TOWING, DISCONNECT POWER TO THE SYSTEM BY, TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RIGHT KICK PANEL AREA TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. RAS ONLY - CLEAR 2140 NOTE EVEN RAS (4X2) EQUIPPED VEHICLES REQUIRE STORING RIDE HEIGHT AND TOGGLING FRONT TO "ON" TO CLEAR A CK SUSP LIGHT/214O CODE. THIS ALLOWS THE MODULE TO STORE THE VOLTAGE WITH NO FRONT HEIGHT SENSOR PRESENT, AND MUST BE DONE EVEN WITH CONVENTIONAL (STEEL COIL) FRONT SUSPENSION. 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON", press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step # 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional (on-demand) test is in process. As test completes, verify a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off. 4WAS - CLEAR 2140 DTC - Mechanical NOTE OBSERVE AND REPAIR ANY DAMAGED PARTS OR SYSTEM LEAKS, INSPECTING THE AIR LINE UNION LOCATED UNDER THE BRAKE MASTER CYLINDER FIRST. IF BRAKE FLUID HAS DAMAGED THE LINE, REPLACE THEN REROUTE NEW AIR LINE AWAY FROM AN ORIENTATION DIRECTLY UNDER THE MASTER CYLINDER. BRUSH A SOAPY WATER SOLUTION ON REMAINING SYSTEM CONNECTIONS, INCLUDING INLINE AND "T" UNIONS; AIR LINE RUB POINTS; COMPRESSOR FITTINGS; GATE AND FILL SOLENOIDS; AND AIR SHOCKS/SPRINGS. KEEP IN MIND THAT AIR SPRING LEAKS WHERE THE BAG FOLDS OVER ITSELF MAY NOT BE IMMEDIATELY OBVIOUS WITHOUT CYCLING THE SUSPENSION THROUGH DIFFERENT HEIGHTS. IF AIR BUBBLES ARE DETECTED, REPAIR AS NECESSARY THEN RETEST TO ENSURE LEAK-FREE CONNECTIONS BEFORE COMPLETING THE STEPS BELOW. 1. Bring the vehicle to kneel height by turning ignition key off, gear lever in park, doors closed for up to 30 seconds on level ground. Listen for compressor's vent solenoid to release air from lines before proceeding. Venting should occur within approximately one minute of closing all doors Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 9374 with the key in the "off" position. 2. Erase the module's memory: ^ Trigger 4WAS active commands, PARAMETER RESET (Clear Ride Height) WARNING DO NOT RESET REAR HEIGHT AT THIS TIME! ^ Trigger thru warning message, then toggle FRONT CLR from "OFF" to "ON" Press Cancel NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION! 3. You have now cleared the front kneel voltage stored in the module and B2140 will be present on next key-up. 4. Bleed air from front shocks: ^ Mark existing torsion bar setting, then back off the torsion bar adjustment bolt several turns (until approximately 40 mm (1.5") distance from the bolt head to the bottom surface of the torsion bar adjuster is reached) ^ Select AIR SUSP CNTRL from active command menu (NGS will return to this after previous steps) ^ Trigger VENT FRONT, then wait several seconds for air to vent. Press Cancel to exit. 5. Adjust torsion bars per Workshop Manual section 204-01B. NOTE LEAVE THE NGS CONNECTED IN ACTIVE COMMAND MODES (ENTERED IN STEP 4) 50 THE SYSTEM REMAINS IN DIAGNOSTIC MODE AND NOT OPERATIONAL MODE. 6. Finish by performing the following electrical front height reset steps. 4WAS - CLEAR 2140 DTC - Electrical 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON". press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional on-demand test is in process. As test completes, verity a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off and vehicle height settles out as compressor fills air bladders/shocks. NOTE FOR OTHER AIR SUSPENSION CONCERNS, REFER TO THE APPROPRIATE WORKSHOP MANUAL SECTIONS: 204-05A FOR VEHICLE DYNAMIC SUSPENSION - REAR, OR SECTION 204-05B FOR VEHICLE DYNAMIC SUSPENSION - 4 WHEEL. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 98-25-4 > Dec > 98 > Suspension - Warning Lamp ON/DTC's C1770/C1845 Suspension Control Module: Customer Interest Suspension - Warning Lamp ON/DTC's C1770/C1845 Article No. 98-25-4 12/21/98 SUSPENSION - CHECK SUSPENSION LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) C1770 AND/OR C1845 STORED IN MEMORY - VEHICLES BUILT THROUGH 10/1/1998 LIGHT TRUCK: 1997-99 EXPEDITION 1998-99 NAVIGATOR ISSUE Some vehicles equipped with air suspension may exhibit an intermittent check suspension lamp on and Diagnostic Trouble Code (DTC) C1770 and/or C1845 illuminated. Vehicles with these codes may not exhibit any ride height concerns. This may be caused by the air suspension control module. ACTION Replace the air suspension control module with a revised air suspension control module and recalibrate ride height. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Connect New Generation Star (NGS) Tester and go to Air Suspension menu to retrieve stored codes. Confirm that you have code C1770 and/or C1845 in memory. If you have any other codes, proceed with appropriate pinpoint tests in the 1998 Expedition/Navigator Workshop Manual, Section 204-OSA (Rear) or 204-05B (4-Wheel). 2. With NGS Tester, run the air suspension On-Demand self test. If you have any codes, proceed with appropriate pinpoint tests in the Workshop Manual, Section 204-OSA or 204-05B. 3. With NGS Tester, select Active Command Modes menu and manually raise and lower vehicle per Ride Height Adjustment procedure, 1998 Workshop Manual, Section 204-OSA or 204-05B. Monitor vehicle height changes. If vehicle does not respond, follow pinpoint tests for pneumatic failures. If vehicle does function properly, continue with Step 4. 4. Replace air suspension control module per the 1998 Workshop Manual, Section 204-OSA or 204-05B. NOTE A NEW OR EXCHANGED AIR SUSPENSION CONTROL MODULE REQUIRES THAT THE RIDE HEIGHT ADJUSTMENT CALIBRATION PROCESS BE PERFORMED; REFER TO FRONT RIDE HEIGHT RESETTING-CLEAR B2140 DTC. PART NUMBER PART NAME F7SZ-5A919-DB Air Suspension Module (1997-98) XL1Z-5A919-AA Air Suspension Module (1999) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982504A Perform Diagnostics, Install 1.2 Hrs. Air Suspension Module, And Perform Ride Height Adjustment Calibration Process DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Technical Service Bulletin # 01-12-8 Date: 010625 Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Article No. 01-12-8 06/25/01 ^ SUSPENSION - AIR SUSPENSION - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE ^ ELECTRICAL - LAMP - AIR SUSPENSION LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE FORD: 1997-2001 EXPEDITION LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit a check suspension lamp ON with Diagnostic Trouble Codes (DTC's) B2140 or C2140 even after the Air Suspension switch in the upper RH kick panel has been turned on. This may occur at pre-delivery, following suspension service, or after Air Suspension module replacement. This may be caused by the ride height calibration. ACTION Adjust and/or recalibrate ride height as necessary using the NGS (New Generation Star) Tester. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011208A Recalibrate Ride Height 0.2 Hr. For Rear Air Suspension (R.A.S.) 4X2 Vehicles Only 011208B Recalibrate Ride Height 0.5 Hr. For 4 Wheel Air Suspension (4W.A.S.) (Includes Time To Adjust Torsion Bars 4X4 Vehicles Only) DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000, 390000 Service Procedure NOTE DURING PDI (PRE-DELIVERY INSPECTION) IF "CK SUSP" LIGHT IS ON, PRIOR TO SENDING TO SERVICE, VERIFY SWITCH IN UPPER RIGHT KICK PANEL IS ON. THIS SWITCH IS TURNED OFF DURING VEHICLE SHIPMENT TO PREVENT MODULE FROM SEEKING TRIM HEIGHT WHILE SECURED DOWN FOR TRANSPORT. NOTE AN INADVERTENT B2140 OR C2140 MAY RESULT IF A PARAMETER RESET (CLEAR RIDE HEIGHT) IS SELECTED UNDER NGS ACTIVE COMMANDS, THEN CANCELLED OUT. NOTE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 9384 THE AIR SUSPENSION CONTROL MODULE PART NUMBER IS INTERCHANGEABLE BETWEEN THE REAR AIR SUSPENSION (RAS) AND 4-WHEEL AIR SUSPENSION (4WAS) SYSTEMS, BUT ONCE THE MODULE IS INSTALLED, THE VEHICLE WILL THEN DETERMINE WHETHER VEHICLE IS 4X2 (RAS) OR 4X4 (4WAS) BASED ON VEHICLE HARNESS INPUTS. NOTE MODULES ARE PRE-PROGRAMMED TO SEEK 2.66 VOLTS + 1.02 VOLTS FROM REAR HEIGHT SENSOR (RHGSTEN PARAMETER IDENTIFIER OR PID) AT TRIM HEIGHT. HOWEVER, A NEW OR SWAPPED MODULE REQUIRES CALIBRATION PER STEPS BELOW TO CLEAR A 2140 (INITIALIZATION FAILURE) CODE. NOTE PERFORM 4WAS-AIR SUSP/EVO (ELECTRONIC VARIABLE ORIFICE STEERING) SELF TEST AND MAKE NECESSARY REPAIRS FOR ANY OTHER AIR SUSPENSION DTC'S THAT ARE PRESENT BEFORE ADDRESSING B2140/C2140. WARNING WARNING: BEFORE REPLACING ANY AIR SUSPENSION COMPONENTS, HOISTING, JACKING, OR TOWING, DISCONNECT POWER TO THE SYSTEM BY, TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RIGHT KICK PANEL AREA TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. RAS ONLY - CLEAR 2140 NOTE EVEN RAS (4X2) EQUIPPED VEHICLES REQUIRE STORING RIDE HEIGHT AND TOGGLING FRONT TO "ON" TO CLEAR A CK SUSP LIGHT/214O CODE. THIS ALLOWS THE MODULE TO STORE THE VOLTAGE WITH NO FRONT HEIGHT SENSOR PRESENT, AND MUST BE DONE EVEN WITH CONVENTIONAL (STEEL COIL) FRONT SUSPENSION. 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON", press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step # 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional (on-demand) test is in process. As test completes, verify a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off. 4WAS - CLEAR 2140 DTC - Mechanical NOTE OBSERVE AND REPAIR ANY DAMAGED PARTS OR SYSTEM LEAKS, INSPECTING THE AIR LINE UNION LOCATED UNDER THE BRAKE MASTER CYLINDER FIRST. IF BRAKE FLUID HAS DAMAGED THE LINE, REPLACE THEN REROUTE NEW AIR LINE AWAY FROM AN ORIENTATION DIRECTLY UNDER THE MASTER CYLINDER. BRUSH A SOAPY WATER SOLUTION ON REMAINING SYSTEM CONNECTIONS, INCLUDING INLINE AND "T" UNIONS; AIR LINE RUB POINTS; COMPRESSOR FITTINGS; GATE AND FILL SOLENOIDS; AND AIR SHOCKS/SPRINGS. KEEP IN MIND THAT AIR SPRING LEAKS WHERE THE BAG FOLDS OVER ITSELF MAY NOT BE IMMEDIATELY OBVIOUS WITHOUT CYCLING THE SUSPENSION THROUGH DIFFERENT HEIGHTS. IF AIR BUBBLES ARE DETECTED, REPAIR AS NECESSARY THEN RETEST TO ENSURE LEAK-FREE CONNECTIONS BEFORE COMPLETING THE STEPS BELOW. 1. Bring the vehicle to kneel height by turning ignition key off, gear lever in park, doors closed for up to 30 seconds on level ground. Listen for compressor's vent solenoid to release air from lines before proceeding. Venting should occur within approximately one minute of closing all doors Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 9385 with the key in the "off" position. 2. Erase the module's memory: ^ Trigger 4WAS active commands, PARAMETER RESET (Clear Ride Height) WARNING DO NOT RESET REAR HEIGHT AT THIS TIME! ^ Trigger thru warning message, then toggle FRONT CLR from "OFF" to "ON" Press Cancel NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION! 3. You have now cleared the front kneel voltage stored in the module and B2140 will be present on next key-up. 4. Bleed air from front shocks: ^ Mark existing torsion bar setting, then back off the torsion bar adjustment bolt several turns (until approximately 40 mm (1.5") distance from the bolt head to the bottom surface of the torsion bar adjuster is reached) ^ Select AIR SUSP CNTRL from active command menu (NGS will return to this after previous steps) ^ Trigger VENT FRONT, then wait several seconds for air to vent. Press Cancel to exit. 5. Adjust torsion bars per Workshop Manual section 204-01B. NOTE LEAVE THE NGS CONNECTED IN ACTIVE COMMAND MODES (ENTERED IN STEP 4) 50 THE SYSTEM REMAINS IN DIAGNOSTIC MODE AND NOT OPERATIONAL MODE. 6. Finish by performing the following electrical front height reset steps. 4WAS - CLEAR 2140 DTC - Electrical 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON". press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional on-demand test is in process. As test completes, verity a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off and vehicle height settles out as compressor fills air bladders/shocks. NOTE FOR OTHER AIR SUSPENSION CONCERNS, REFER TO THE APPROPRIATE WORKSHOP MANUAL SECTIONS: 204-05A FOR VEHICLE DYNAMIC SUSPENSION - REAR, OR SECTION 204-05B FOR VEHICLE DYNAMIC SUSPENSION - 4 WHEEL. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 98-25-4 > Dec > 98 > Suspension - Warning Lamp ON/DTC's C1770/C1845 Suspension Control Module: All Technical Service Bulletins Suspension - Warning Lamp ON/DTC's C1770/C1845 Article No. 98-25-4 12/21/98 SUSPENSION - CHECK SUSPENSION LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) C1770 AND/OR C1845 STORED IN MEMORY - VEHICLES BUILT THROUGH 10/1/1998 LIGHT TRUCK: 1997-99 EXPEDITION 1998-99 NAVIGATOR ISSUE Some vehicles equipped with air suspension may exhibit an intermittent check suspension lamp on and Diagnostic Trouble Code (DTC) C1770 and/or C1845 illuminated. Vehicles with these codes may not exhibit any ride height concerns. This may be caused by the air suspension control module. ACTION Replace the air suspension control module with a revised air suspension control module and recalibrate ride height. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Connect New Generation Star (NGS) Tester and go to Air Suspension menu to retrieve stored codes. Confirm that you have code C1770 and/or C1845 in memory. If you have any other codes, proceed with appropriate pinpoint tests in the 1998 Expedition/Navigator Workshop Manual, Section 204-OSA (Rear) or 204-05B (4-Wheel). 2. With NGS Tester, run the air suspension On-Demand self test. If you have any codes, proceed with appropriate pinpoint tests in the Workshop Manual, Section 204-OSA or 204-05B. 3. With NGS Tester, select Active Command Modes menu and manually raise and lower vehicle per Ride Height Adjustment procedure, 1998 Workshop Manual, Section 204-OSA or 204-05B. Monitor vehicle height changes. If vehicle does not respond, follow pinpoint tests for pneumatic failures. If vehicle does function properly, continue with Step 4. 4. Replace air suspension control module per the 1998 Workshop Manual, Section 204-OSA or 204-05B. NOTE A NEW OR EXCHANGED AIR SUSPENSION CONTROL MODULE REQUIRES THAT THE RIDE HEIGHT ADJUSTMENT CALIBRATION PROCESS BE PERFORMED; REFER TO FRONT RIDE HEIGHT RESETTING-CLEAR B2140 DTC. PART NUMBER PART NAME F7SZ-5A919-DB Air Suspension Module (1997-98) XL1Z-5A919-AA Air Suspension Module (1999) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982504A Perform Diagnostics, Install 1.2 Hrs. Air Suspension Module, And Perform Ride Height Adjustment Calibration Process DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Locations > Electronic Level Control (ELC) Module Suspension Control Module: Locations Electronic Level Control (ELC) Module Instrument Panel View The 4 Wheel Air-Suspension Module is located behind the center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Locations > Electronic Level Control (ELC) Module > Page 9392 Suspension Control Module: Locations Suspension Control Module Instrument Panel View The 4 Wheel Air-Suspension Module is located behind the center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Diagrams > Electronic Level Control (ELC) Module Suspension Control Module: Diagrams Electronic Level Control (ELC) Module 4 Wheel Air Suspension Module (C295) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Diagrams > Electronic Level Control (ELC) Module > Page 9395 4 Wheel Air Suspension Module (C296) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Diagrams > Electronic Level Control (ELC) Module > Page 9396 Suspension Control Module: Diagrams Suspension Control Module 4 Wheel Air Suspension Module (C295) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Diagrams > Electronic Level Control (ELC) Module > Page 9397 4 Wheel Air Suspension Module (C296) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Description and Operation > Four Wheel Air Suspension Suspension Control Module: Description and Operation Four Wheel Air Suspension A microcontroller-based electronic module controls the air compressor motor (through a solid state relay), and all system solenoids. The module also provides power to front and rear height sensors. The module controls vehicle height adjustments by monitoring the two height sensors, vehicle speed, a steering sensor, acceleration input, the door ajar signal, transfer case signals, and the brake switch. The module also conducts all fail-safe and diagnostic strategies and contains self-test and communication software for testing of the vehicle and related components. The control module is mounted in the passenger compartment inside the instrument panel, above the radio and temperature controls. The air suspension system control module monitors and controls the system through a 32-pin two-way connector. The control module is keyed so that it cannot be plugged into an incorrect harness. There are two sides of the harness connection to the module. Each is uniquely colored and keyed to prevent reversing the connections. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Description and Operation > Four Wheel Air Suspension > Page 9400 Suspension Control Module: Description and Operation Rear Air Suspension A microcontroller-based electronic module controls the air compressor motor (through a solid state relay), and all system solenoids. The module also provides power to the rear height sensor. The module controls vehicle height adjustments by monitoring the one height sensor, vehicle speed, a steering sensor, acceleration input, the door ajar signal, transfer case signals, and the brake switch. The module also conducts all fail-safe and diagnostic strategies and contains self-test and communication software for testing of the vehicle and related components. The control module is mounted in the passenger compartment inside the instrument panel, above the radio and temperature controls. The air suspension system control module monitors and controls the system through a 32-pin two-way connector. The control module is keyed so that it cannot be plugged into an incorrect harness. There are two sides of the harness connection to the module. Each is uniquely colored and keyed to prevent reversing the connections. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Service and Repair > Four Wheel Air Suspension Suspension Control Module: Service and Repair Four Wheel Air Suspension REMOVAL 1. Disconnect battery ground cable. 2. Remove the center instrument panel finish panel. 4 3. Disconnect the transfer case rotary control switch electrical connector. 4. Remove the steering column cover trim panel. 5. Remove the headlamp switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Service and Repair > Four Wheel Air Suspension > Page 9403 6. Remove the LH instrument panel finish panel. (1) Remove the screws. (2) Remove the instrument panel finish panel. 7. Remove the instrument cluster panel. (1) Remove the screws. (2) Remove the instrument cluster panel. 8. Remove the control module mounting bracket screws. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Service and Repair > Four Wheel Air Suspension > Page 9404 9. Lift control module and mounting bracket from instrument panel and disconnect the control module electrical connectors. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Service and Repair > Four Wheel Air Suspension > Page 9405 Suspension Control Module: Service and Repair Rear Air Suspension REMOVAL 1. Disconnect battery ground cable. 2. Remove the center instrument panel finish panel. 3. Remove the steering column cover trim panel. 4. Remove the headlamp switch. 5. Remove the LH instrument panel finish panel. (1) Remove the screws. (2) Remove the instrument panel finish panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Service and Repair > Four Wheel Air Suspension > Page 9406 6. Remove the instrument chaster panel. (1) Remove the screws. (2) Remove the instrument cluster panel. 7. Remove the control module mounting bracket screws. 8. Lift the control module and mounting bracket from the instrument panel and disconnect the control module electrical connectors. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Mode Switch > Component Information > Specifications Suspension Mode Switch: Specifications Switch Bracket Mounting Bolt ........................................................................................................................................... 10.2-13.8 Nm (91-123 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Mode Switch > Component Information > Specifications > Page 9410 Suspension Mode Switch: Description and Operation The air suspension switch is located behind the RH kick panel on a mounting bracket. The switch interrupts power to the control module. The air suspension switch supplies a signal to the control module. Without the control module receiving this signal the load leveling system is inoperative and will not react when rear of the vehicle is raised or lowered. If the air suspension is disabled by turning off air suspension switch, a "CHECK SUSP" will appear in the RH corner of the cluster with the ignition in the run position. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Mode Switch > Component Information > Specifications > Page 9411 Suspension Mode Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front door scuff plate. 3. Remove the cowl side trim panel. 4. Disconnect the air suspension switch electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Mode Switch > Component Information > Specifications > Page 9412 5. Remove the air suspension switch bracket mounting bolt. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal Suspension Spring ( Coil / Leaf ): Service and Repair Removal 1. Loosen the lug nuts. (1) Remove the center cap. (2) With the weight of the vehicle on the wheels, loosen, but do not remove, the lug nuts. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and the wheel bearings. 2. Raise and support the vehicle. 3. Remove the wheel and tire assembly. (1) Remove the lug nuts. (2) Remove the tire and wheel assembly. 4. Remove the driveshaft. 5. Disconnect the rear brake anti-lock sensor (ABS) electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal > Page 9417 6. Relieve the tension on the parking brake system. (1) Pull the front parking brake cable and conduit. (2) Insert a suitable retainer into the parking brake control NOTE: Make sure the parking brake control is fully released. 7. Disconnect the rear parking brake cable and conduit from the rear axle. (1) Remove the rear parking brake cable and conduit from the rear axle bracket assembly. (2) Remove the cable from the caliper. ^ Repeat for other side. 8. Position the disc brake caliper aside. (1) Remove the bolts. (2) Secure the caliper aside with wire. ^ Repeat for other side. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal > Page 9418 9. Disconnect the axle vent tube. 10. Disconnect the stabilizer bar from the rear axle. (1) Remove the bolts from each stabilizer bar retainer. (2) Remove the retainers. 11. Use Hi-Lift Jack to support the rear axle. 12. Remove the lower shock absorber nut and bolt. ^ Repeat for other side. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal > Page 9419 13. Remove the rear axle to trackbar assembly bolt. 14. Remove the rear suspension lower arm assembly to the axle bolt. ^ Repeat for other side. 15. Remove the rear suspension upper arm assembly to the rear axle bolt. ^ Repeat for other side. 16. Lower the rear axle and remove the coil spring. (1) Lower the rear axle. (2) Remove spring. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal > Page 9420 Suspension Spring ( Coil / Leaf ): Service and Repair Installation NOTE: Do not tighten any nuts or bolts until the rear suspension is raised so that the rear suspension lower arms are parallel to the ground. Once in position, tighten all the nuts and bolts to specification. 1. Install the rear coil spring. (1) Position the spring. (2) Raise the axle. 2. Position the rear suspension upper arm assemblies to the axle and install the bolts. 3. Position the rear suspension lower arm assemblies to the axle and install the bolts. 4. Position the trackbar assembly to the axle and install the bolts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal > Page 9421 5. Position the shock absorbers to the axle and install the bolts. 6. Position the stabilizer bar to the axle and install the stabilizer bar retainers and bolts. 7. Position the disc brake caliper. (1) Position caliper. (2) Install the bolts. 8. Connect parking brake cables and conduit to the axle. (1) Install the cable and conduit to the lever. (2) Install the cable and conduit to rear axle bracket assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal > Page 9422 9. Install the tire and wheel assembly. (1) Position the tire and wheel assembly. (2) Install the lug nuts and lower the vehicle. (3) Tighten the lug nuts in sequence. (4) Install the wheel cover. 10. Remove the pin from parking brake control assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications Suspension Strut / Shock Absorber: Specifications TORQUE SPECIFICATIONS Front Shock Lower Bolt/Nut .................................................................................................................................................... 77-103 Nm (57-75 ft. lbs.) Rear Shock Absorber Nuts ....................................................................................................................................................... 86-114 Nm (65-85 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Page 9426 Suspension Strut / Shock Absorber: Description and Operation NOTE: For information on the front air shock absorbers. The shock absorbers: ^ Are sealed hydraulic and telescopic in design. ^ Are direct double-acting type. ^ Are replaced as a complete assembly. ^ Provide continuous ride dampening. ^ Are mounted between the frame and rear axle housing (rear shock absorbers). ^ Are mounted between the front suspension lower arm and the upper shock absorber mount (front shock absorbers). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Suspension Strut / Shock Absorber: Initial Inspection and Diagnostic Overview CAUTION : The low pressure gas shock absorbers are charged with nitrogen gas to 931 kPa (135 psi) for 1-3/16 inch bore, and 1034 kPa (150 psi) for 1-3/8 inch bore. Do not attempt to open, puncture, or apply heat to the shock absorbers. All vehicles are equipped with low pressure gas-filled hydraulic shock absorbers of the direct acting type. They are non-adjustable and non-refillable. They cannot be serviced as cartridges and must be serviced as shock assemblies. Before replacing a shock absorber, check the action of the shock absorbers as follows. 1. Check all tires for proper inflation pressure. 2. Check tire condition to confirm proper front end alignment, tire balance and overall tire condition such as separation or bulges. 3. Check the vehicle for optional suspension equipment such as heavy-duty handling or trailer tow suspensions. These suspensions will have a firmer feeling ride than standard suspensions. 4. Check the vehicle attitude for evidence of possible overload or sagging. Many times, front springs and front shock absorbers are replaced in an effort to solve a vehicle sag concern. Shock absorbers are, by design, hydraulic damping units only and unlike suspension springs, do not support any suspension loads. Therefore, replacing a shock absorber will not correct a vehicle sag concern. 5. Road test the vehicle to confirm the customer concern. 6. Make sure the shock absorber is securely and properly installed. 7. Check the shock absorber insulators for damage and wear. Replace any worn or damaged insulators and tighten attachments to the specified torque (on a shock absorber which incorporates internal insulators, replace the shock absorbers). 10. Inspect the shock absorber for evidence of fluid leakage. Leakage is a condition in which the entire shock body is covered with oil, and the oil will drip from the shock onto the pavement. A light film of oil (weepage) on the upper portion of the front shock absorber is permissible and is a result of proper shock lubrication. Weepage is a condition in which a thin film of oil may be deposited on the shock outer tube (body) and is normally noticed due to the collection of dust in this area. Front shock absorbers which exhibit this weepage condition are functional units and should not be replaced. 11. If leakage exists: ^ Make sure the fluid observed is not from sources other than the front shock absorber. ^ Replace the worn or damaged front shock absorber. 12. Disconnect the lower end of the shock absorber. 13. Extend and compress the shock absorber as fast as possible, using as much travel as possible. Action should become smooth and uniform throughout each stroke. Higher resistance on extension than on compression is a normal condition. Faint swish noises are also normal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9429 Suspension Strut / Shock Absorber: Component Tests and General Diagnostics Bench Test The front shock absorbers are gas-pressurized, which results in their being fully extended when not restrained. If a front shock absorber does not fully extend, it is damaged and should be replaced. With the front shock absorber in the normal upright position, compress it and allow it to extend three times to purge the pressure chamber of any gas that may have been introduced during handling. Place the front shock absorber right side up in a vise. Hand-stroke the front shock absorber as fast as possible using as much travel as possible. Action should be smooth and uniform throughout each stroke. Higher resistance on extension than on compression is normal. The following conditions are abnormal: ^ A lag or skip at a reversal of travel near mid-stroke when the front shock absorber is properly primed and in the installed position. ^ Seizing. ^ Noise, other than a faint swish, such as a clicking upon fast stroke reversal. ^ Excessive fluid leakage. ^ With rod fully extended, any lateral motion of rod in relation to outer cylinder. ^ If front shock absorber action remains erratic after purging air, install a front shock absorber, replacing only the damaged front shock absorber. Front shock absorbers do not need to be replaced in pairs. Hoist Check WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 1. Noise: Check for loose/damaged suspension or shock attachments when locating a noise symptom. Verify that all the attachments or the suspension components and the front springs and front shock absorbers are in good condition and tight. Replace any worn or damaged parts or components. 2. Bottom/Hopping: Check the condition of the rubber suspension travel stops (front suspension bumpers). Examine them for evidence of previous overload or damaged components; replace them if they are worn or missing. 3. Force-Check: Support the front axle and remove the lower front shock attachment. Stroke the front shock body using as much travel as possible. The action should be smooth and uniform throughout each stroke. Damping forces should be equivalent on both sides of the vehicle. 4. Replace only the worn or damaged front shock absorber. In the past, it was recommended that front shock absorbers be replaced in pairs if one unit became unserviceable. Improved sealing, new materials, design, and improved rod machining and hardening techniques have added to the reliability of shock absorbers. Therefore, front shock absorbers no longer need to be replaced in pairs when only one unit is not serviceable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Air Shock Absorber Suspension Strut / Shock Absorber: Service and Repair Front Air Shock Absorber Air Spring - Front Shocks Removal 1. WARNING: DO NOT REMOVE AN AIR SHOCK UNDER ANY CIRCUMSTANCES WHEN THERE IS PRESSURE IN THE AIR SHOCK. DO NOT REMOVE ANY COMPONENTS SUPPORTING AN AIR SHOCK WITHOUT EITHER EXHAUSTING THE AIR OR PROVIDING SUPPORT FOR THE AIR SHOCK TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. Bleed the air from the air suspension system; refer to the procedure in this section. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Raise and support the vehicle; refer to Section 100-02. 3. Remove the air shock lower nut and bolt. 4. WARNING: DISCONNECTING ANY AIR LINE THAT IS CONNECTED TO AN AIR SHOCK CAN CAUSE PERSONAL INJURY OR DAMAGE TO COMPONENTS AS HIGH PRESSURE AIR IS VENTED UNCONTROLLED. BEFORE DISCONNECTING AIR LINES CONNECTED TO AIR SHOCKS, USE NGS TESTER ACTIVE COMMAND VENT FNT TO RELIEVE ALL PRESSURE. CAUTION: For removal of LH front air shock absorber, always disconnect top of front height sensor from the upper frame bracket to prevent damage to the height sensor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Air Shock Absorber > Page 9432 Disconnect the air line. - Push the red ring in and hold firmly to remove the air line. 5. Remove the air shock upper nut and grommet. 6. Remove the air shock. Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Air Shock Absorber > Page 9433 1. To install, reverse the removal procedure. 2. Inflate the air shocks. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Air Shock Absorber > Page 9434 Suspension Strut / Shock Absorber: Service and Repair Rear REMOVAL 1. Loosen the lug nuts. (1) Remove the center cap with plastic coated tip of lug wrench. (2) With the weight of the vehicle on the wheels, loosen the lug nuts. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and the wheel bearings. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Raise and support the vehicle. 3. Remove the tire and wheel assembly. (1) Remove the lug nuts. (2) Remove the tire and wheel assembly. 4. Use Hi-Lift Jack to support the rear axle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Air Shock Absorber > Page 9435 5. Remove the upper shock absorber nut and bolt. 6. Remove the shock absorber. (1) Remove the lower shock absorber nut and bolt. (2) Remove shock absorber. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Air Shock Absorber > Page 9436 INSTALLATION 1. To install reverse the removal procedure. WARNING: ALWAYS REMOVE ANY CORROSION, DIRT OR FOREIGN MATERIAL PRESENT ON THE MOUNTING SURFACES OF THE WHEEL OR THE SURFACE OF THE WHEEL HUB, BRAKE DRUM OR FRONT DISC BRAKE ROTOR THAT CONTACTS THE WHEEL. INSTALLING WHEELS WITHOUT PROPER METAL TO METAL CONTACT AT THE WHEEL MOUNTING SURFACES CAN CAUSE THE LUG NUTS TO LOOSEN AND COULD ALLOW THE WHEEL TO COME OFF WHILE THE VEHICLE IS IN MOTION, CAUSING LOSS OF CONTROL. NOTE: Tighten the lug nuts in the sequence indicated. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Air Shock Absorber > Page 9437 Suspension Strut / Shock Absorber: Service and Repair Front Shock Absorber REMOVAL 1. Hold the shock absorber stem and remove the upper front shock absorber nut, and washer assembly. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Raise and support the vehicle. 3. Remove the shock absorber. (1) Remove the lower nut and bolt. (2) Remove the shock absorber. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Air Shock Absorber > Page 9438 INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Specifications Suspension Travel Bumper: Specifications Axle Bumper Bolt ................................................................................................................................. ..................................... 34-46 Nm (26-34 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair Torsion Bar: Service and Repair REMOVAL 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Make preliminary adjustment references. (1) Make an alignment mark on the torsion bar and the torsion bar crossmember support. (2) Measure and record the length. 3. Relieve the torsion bar tension. (1) Remove the torsion bar adjuster bolt. (2) Install Torsion Bar Tool with Torsion Bar Tool Adapters in the B slots on Torsion Bar Tool. (3) Tighten Torsion Bar Tool until the torsion bar adjuster lifts off of the adjuster nut. (4) Remove the torsion bar adjuster nut. (5) Remove Torsion Bar Tool. (6) Remove the torsion bar adjuster. ^ Repeat for the other side. 4. Remove the torsion bars. (1) Remove the torsion bar crossmember support bolts and nuts. (2) Remove the torsion bar crossmember support. (3) Remove the torsion bars. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Page 9445 INSTALLATION 1. Install the torsion bar. (1) Position the torsion bars. (2) Position the torsion bar crossmember support. (3) Install the torsion bar crossmember support bolts and nuts. 2. Load the torsion bar. (1) Install the torsion bar adjuster. (2) Install Torsion Bar Tool with torsion BarTool Adapters in the B slots on the torsion bar tool. (3) Tighten Torsion Bar Tool to load the torsion bar. (4) Install the torsion bar adjuster nut. (5) Install the torsion bar adjuster bolt. (6) Remove Torsion Bar Tool. ^ Turn the torsion bar adjuster until the reference marks align. ^ Repeat for the other side. 3. Adjust the ride height. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > Recalls for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket Technical Service Bulletin # 96S60 Date: 970201 Recall - Rear Track Arm/Control Arm Bracket SAFETY RECALL 96960 Certain 1997 Model Year Expeditions Built at Michigan Truck Plant - Rear Axle Track Bar Bracket/Lower Control Arm Bracket ^ Dealer Letter ^ Special Recall Parts Announcement ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information - Part 1: Axle Inspection and, if Necessary, Replacement ^ Attachment III ^ Technical Information - Part 2: Track Bar Bracket Inspection/Modification ^ Attachment IV ^ Revised Technical Instructions - March 11, 1997 ^ Attachment V ^ Revised Technical Instructions and Labor Allowances ^ Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > Recalls for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9454 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > Recalls for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9455 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. Please Note Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,000 per vehicle. Promptly Correct Affected vehicles on the enclosed list. Other eligible vehicles which are brought to your dealership. Dealer-Owner Contact Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Schedule a service date. Regional Contact Advise regional office if: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > Recalls for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9456 ^ an owner cannot be contacted. ^ an owner does not make a service date. Claims Submission Enter claims using DWE. See ACESII Manual, Sections 5 and 6. Warranty and Policy Manual See Sections 5 and 6 of the ACESII Manual. Refunds See Section 3-59 of the ACESII Manual. Rental Cars If an inspection reveals that a new axle must be installed, Ford Motor Company will pay for a loaner or rental vehicle, except for fuel, which will be at owner's expense. Enter the word "LOANER" plus the number of days the vehicle was used in the Miscellaneous Expense area. Attachment II - Labor and Parts Information 1997 Model Year Expedition Track Bar Bracket/Lower Control Arm Bracket Labor Allowances NOTE: Only submit one of the above Labor Operations per vehicle. Be sure to select the correct operation. The labor operations above (except Inspection), contain time to re-torque the lug nuts after the 800 km (500 mile) interval as recommended in the vehicle Owner Guide. Parts Requirements Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > Recalls for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9457 A small number of "seed stock" parts will be direct shipped to each Ford Division dealer for this recall as follows: 1 part to dealers with 1 to 5 affected vehicles* 3 parts to dealers with 6 to 9 affected vehicles* 5 parts to dealers with 10 or more affected units* *Based on Ford Motor Company Records Shipment of seed stock parts is expected to be completed by February 21, 1997. Order additional parts by calling Renkim (1-800-325-5621). Be prepared to provide the affected VIN number when calling for additional parts. NOTE: If inspection reveals that a new axle assembly is required, call 1-800-325-5621. When calling this number, be prepared to give the following information: NOTE:you will be charged for the axle assembly. ^ Safety Recall 96S60 ^ VIN Number ^ P & A Code ^ Axle Code (See Attachment III for axle codes) ^ Shipping Address ^ Person to whom parts should be sent ^ Telephone Number NOTE: Removed axles must be returned. See instructions below. Axles which are needlessly replaced will be subject to chargeback. Dealer Price For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book Excess Stock Return Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Parts Return You are required to return the removed axle assembly using the shipping container in which the replacement was received. Store the old axle assembly for receipt of the Direct Ship Document that will be on your Overnite Parts register. Clearly mark on the axle assembly Safety Recall 96S60. UPON RECEIPT OF THE DIRECTSHIP DOCUMENT, ship the removed axle assembly, freight prepaid, to: Sterling Axle Plant Attn: Mr. Monzie Edmonds 39000 Mound Road Sterling Heights, Michigan 48301 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > Recalls for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9458 Attachment III - Technical Information Part 1: Axle Rear Axle Lower Control Arm Bracket Inspection and/or Track Bar Bracket Modification Affected Vehicles: 1997 Expedition built at the Michigan Truck Plant from March 1, 1996 through October 10,1996 NOTE: This program contains two parts: Part 1: Axle inspection and, if necessary, replacement Part 2: Track bar bracket inspection/modification NOTE: It is most efficient to perform both inspections before proceeding further. Part 1: Axle Inspection and, If Necessary, Replacement 1. On vehicles equipped with air suspension, turn air suspension switch off. Switch is located in the right side kick panel. 2. Raise and support vehicle. 3. Inspect both rear axle tubes for date code stamps. Clean paint or undercoating to locate date code. See Figure 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > Recalls for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9459 ^ It date code stamps are present on both rear axle tubes, no service action is required for the rear axle. Go to PART 2. ^ If date code stamps are not on both rear axle tubes, the rear axle must be replaced. Continue on, to order axle. ^ If inspection reveals that the axle must be replaced, check rear axle ID tag for axle ratio code and ring gear diameter, See Figure 2. ^ Cross reference axle ratio code and ring gear diameter in table below to get axle service part number. See Figure 3. ^ Call RENKIM (1-800-325-5621) to order a new axle. When new rear axle is received, proceed to Rear Axle Replacement. Rear Axle Replacement Vehicles Equipped With Rear Air Suspension (See sections for vehicles with rear coil spring suspension) Removal 1. Lower Vehicle 2. Vent air spring air pressure as follows: ^ Turn air suspension switch on. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > Recalls for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9460 ^ Turn the ignition to the run position. ^ Connect the NGS tester to the vehicle. ^ Select 1997 4.6L/5.4L Expedition 4WAS module. ^ Select "Air Suspension Control Mode: under "Active Command Modes" menu. ^ Select "VENT REAR" to deflate rear air springs. ^ Turn air suspension switch off. 3. Install memory saver, then disconnect battery negative terminal. 4. Raise and support vehicle. 5. Remove both rear tire and wheel assemblies. 6. Remove driveshaft retaining bolts, then separate driveshaft from companion flange. 7. Wire driveshaft away from the rear axle. 8. Disconnect rear ABS sensor electrical connector, then detach wiring harness from rear axle. 9. On each side of the vehicle, perform the following: ^ Disconnect parking brake cable from parking brake lever. ^ Separate parking brake cable from disc brake adapter. ^ Remove brake caliper retaining bolts, then position brake caliper away from the rear axle. Do not let caliper hang from the brake hose. ^ Remove O-ring from hub, then remove brake rotor from hub. ^ Remove jounce bumper from axle housing. 10. Remove sway bar retainer-to-rear axle mount retaining bolts. Position sway bar away from rear axle. 11. Disconnect load level sensor from rear axle. 12. Position jack stands under rear axle. 13. Lower vehicle enough to release tension on rear axle attaching points (shock absorbers, control arms). 14. Disconnect track bar from rear axle. Position track bar away from rear axle. 15. On each side of the vehicle, perform the following: ^ Remove upper control arm-to-rear axle retaining bolt. Separate control arm from its mounting. ^ Remove lower control arm-to-rear axle retaining bolt. Separate control arm from its mounting. ^ Remove shock absorber-to-rear axle retaining bolt. Separate shock from its mounting. 16. Disconnect axle vent hose from rear axle. 17. Slowly raise the vehicle. Make sure there are not components that will interfere with vehicle separation from the rear axle. 18. Remove rear axle from jack stands. Installation NOTE: New attaching hardware is provided with the replacement axle assembly. Do not use old attaching hardware. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > Recalls for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9461 NOTE: Refer to the table to cross-reference circled letters to part description. 1. Position new rear axle on jack stands. 2. Position differential nose on an upward angle using third jack stand. This will allow control arms to clear axle when vehicle is lowered. 3. Lower vehicle over axle. NOTE: Do not tighten retaining nuts at this time. 4. Connect the following components to the rear axle: ^ Air springs ^ Lower control arms (use bolt [A] and nut [C]). ^ Upper control arms (use bolt [A] and nut [B]). ^ Shock absorbers (use bolt [I] and nut [J]). ^ Sway bar retainers (use bolt [E] and nut [D]). ^ Track bar (use bolt [F] and nut [G]). 5. Raise and support vehicle. 6. Position hydraulic jack under rear axle. 7. Raise rear axle until lower control arms are parallel to the ground. NOTE: Tighten both left and right sides of a component before proceeding to the next component. 8. Tighten the following components: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > Recalls for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9462 ^ Lower control arm retaining nuts to 128-172 Nm (95-127 lb/ft). ^ Upper control arm retaining nuts to 128-172 Nm (95-127 lb/ft). ^ Shock absorber lower retaining nuts to 88-119 Nm (65-87 lb/ft). ^ Sway bar retainer bolts to 53-72 Nm (39-53 lb/ft). ^ Track bar retaining nut 170-230 Nm (125-169 lb/ft). 9. Connect axle vent hose to the rear axle. 10. Connect the load level sensor to the rear axle. 11. On each side of the vehicle, perform the following: ^ Connect parking brake cable to the parking brake lever. ^ Connect parking brake cable to the disc brake adapter. ^ Install the brake rotor, then the hub O-ring (use O-ring [L]). ^ Position and install the brake caliper. Tighten the retaining bolts to 27 Nm (20 lb/ft). ^ Install jounce bumper onto the rear axle (use screw [H)). Tighten retaining screw to 34-46 Nm (25-33 lb/ft). 12. Route rear ABS sensor wiring harness, then connect rear ABS sensor electrical connector. 13. Align yellow marks on both the driveshaft and companion flange, then install driveshaft retaining bolts (use bolt [K]). Tighten bolts to 88-119 Nm (65-88 lb/ft). WARNING RETIGHTEN AT 800KM (500 MILES) AFTER ANY WHEEL CHANGE OR ANY TIME THE LUG NUTS ARE LOOSENED. WARNING FAILURE TO RETIGHTEN LUG NUTS AT THE MILEAGE SPECIFIED COULD ALLOW WHEELS TO COME OFF WHILE THE VEHICLE IS IN MOTION, POSSIBLY CAUSING LOSS OF VEHICLE CONTROL AND COLLISION. 14. Install both rear tires and wheel assemblies. Tighten wheel nuts in criss-cross pattern to 115-156 Nm (85-115 lb/ft). 15. Lower Vehicle. 16. Turn on air suspension switch. 17. Start and run vehicle. Make sure air suspension system pressurizes the rear air springs. Rear Coil Spring Suspension Vehicles Equipped With Rear Coil Spring Suspension (See previous section for vehicles with rear air suspension) Removal 1. Remove both rear tire and wheel assemblies. 2. Remove driveshaft retaining bolts, then separate driveshaft from companion flange. 3. Wire drive shaft away from the rear axle. 4. Disconnect rear ABS sensor electrical connector, then detach wiring harness from rear axle. 5. On each side of the vehicle, perform the following: ^ Disconnect parking brake cable from parking brake lever. ^ Separate parking brake cable from disc brake adapter. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > Recalls for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9463 ^ Remove brake caliper retaining bolts, then position brake caliper away from the rear axle. Do not let caliper hang from the brake hose. ^ Remove O-ring from hub, then remove brake rotor from hub. ^ Remove jounce bumper from axle housing. 6. Remove sway bar retainer-to-rear axle mount retaining bolts. Position sway bar away from rear axle. 7. Position jack stands under rear axle. 8. Lower vehicle enough to release tension on rear axle attaching points (shock absorbers, control arms). 9. Disconnect track bar from rear axle. Position track bar away from rear axle. 10. On each side of the vehicle, perform the following: ^ Remove upper control arm-to-rear axle retaining bolt. Separate control arm from its mounting. ^ Remove lower control arm-to-rear axle retaining bolt. Separate control arm from its mounting. ^ Remove shock absorber-to-rear axle retaining bolt. Separate shock from its mounting. 11. Disconnect axle vent hose from rear axle. 12. Slowly raise the vehicle. Make sure there are no components that will interfere with vehicle separation from the rear axle. 13. Remove both rear coil springs. 14. Remove rear axle from jack stands. Installation NOTE: New attaching hardware is provided with the replacement axle assembly. Do Not use old attaching hardware. NOTE: Refer to the table to cross-reference circle letters to part description. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > Recalls for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9464 1. Position new rear axle on jack stands. 2. Position differential nose on an upward angle using third jack stand. This will allow control arms to clear axle when vehicle is lowered. 3. Lower vehicle over axle. NOTE: Do not tighten retaining nuts at this time. 4. Connect the following components to the rear axle: ^ Lower control arms (use bolt [A] and nut [C]). ^ Upper control arms (use bolt [A] and but [B)). 5. Raise and support vehicle. 6. Position hydraulic lack under rear axle. 7. Raise rear axle until lower control arms are parallel to the ground. NOTE: Tighten both left and right sides of a component before proceeding to the next component. 8. Tighten the following components: ^ Lower control arm retaining nuts to 128-172 Nm (95-127 lb/ft). ^ Upper control arm retaining nuts to 128-172 (95-127 lb/ft). 9. Lower the rear axle until axle is hanging freely from hydraulic jack. 10. Install both coil springs. 11. Raise rear axle, then connect the following components to the rear axle: ^ Shock absorbers (use bolt [I] and nut [J]). ^ Sway bar retainers (use bolt [E] and nut [D]). ^ Track bar (use bolt [F] and nut [G]). NOTE: Tighten both left and right sides of a component before proceeding to the next component. 12. Tighten the following components: ^ Shock absorber lower retaining nuts to 88-119 Nm (65-87 lb/ft). ^ Sway bar retainer bolts to 53-72 Nm (39-53 lb/ft). ^ Track bar retaining nut 170-230 Nm (125-169 lb/ft). 13. Connect axle vent hose to the rear axle. 14. On each side of the vehicle, perform the following: ^ Connect parking brake cable to the parking brake lever. ^ Connect parking brake cable to the disc brake adapter. ^ Install the brake rotor, then the hub O-ring (use O-ring [L]). ^ Position and install the brake caliper. Tighten the retaining bolts to 27 Nm (20 lb/ft). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > Recalls for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9465 ^ Install jounce bumper onto the rear axle (use screw [H]). Tighten retaining screw to 34-46 Nm (25-33 lb/ft). 15. Route rear ABS sensor wiring harness, then connect rear ABS sensor electrical connector. 16. Align yellow marks on both the driveshaft and companion flange, then install driveshaft retaining bolts (use bolt [K]). Tighten bolts to 88-119 Nm (65-88 lb/ft). WARNING RETIGHTEN AT 800KM (500 MILES) AFTER ANY WHEEL CHANGE OR ANY TIME THE LUG NUTS ARE LOOSENED. WARNING FAILURE TO RETIGHTEN LUG NUTS AT THE MILEAGE SPECIFIED COULD ALLOW WHEELS TO COME OFF WHILE THE VEHICLE IS IN MOTION, POSSIBLY CAUSING LOSS OF VEHICLE CONTROL AND COLLISION. 17. Install both rear tires and wheel assemblies. Tighten wheel nuts in criss-cross pattern to 115-156 Nm (85-115 lb/ft). 18. Lower vehicle. Attachment III - Technical Information - Part 2: Bar Bracket Rear Axle Lower Control Arm Bracket Inspection and/or Track Bar Bracket Modification Affected Vehicles: 1997 Expedition built at the Michigan Truck Plant from March 1, 1996 through October 10, 1996 NOTE: This program contains two parts: Part 1: Axle inspection and, if necessary, replacement Part 2: Track bar bracket inspection/modification Inspection Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > Recalls for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9466 1. Inspect for welds on inside of left track bar bracket. See Figure 4. ^ If welds are present, no track bar bracket service action is required for the vehicle. Lower vehicle and turn air suspension switch on, if equipped. Return vehicle to the customer unless axle is to be replaced. ^ If welds are not present, proceed to Track Bar Bracket Modification. In the rare case where the bracket has been separated from the frame, call Renkim at 1-800-325-5621. Track Bar Bracket Modification 1. Lower vehicle. 2. Remove spare tire assembly. 3. On vehicles equipped with air suspension, vent air spring air pressure as follows: ^ Turn air suspension switch on. ^ Turn the ignition to the run position. ^ Connect the NGS tester to the vehicle. ^ Select 1997 4.6L/5.4L Expedition 4WAS module. ^ Select "Air Suspension Control Mode: under "Active Command Modes" menu. ^ Select "VENT REAR" to deflate rear air springs. ^ Turn air suspension switch off. 4. Install memory saver, then disconnect battery negative cable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > Recalls for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9467 5. Raise and support vehicle. 6. Remove both rear tire and wheel assemblies. 7. Remove 0-rings from both rear hubs. 8. Remove inspection cover from left side frame rail above the rear axle. 9. On vehicles equipped with coil spring suspension, remove left rear coil spring as follows: ^ Place hydraulic jack under axle housing. ^ Raise jack slightly to release tension on rear axle components. ^ Remove both rear shock absorber lower mounting bolts. ^ Remove both sway bar to sway bar link retaining bolts. Position sway bar away from links. ^ Lower jack enough to release spring tension. ^ Remove left rear spring. 10. On vehicles equipped with air suspension, remove left rear air spring as follows: ^ Disconnect air spring electrical connector. ^ Disconnect air spring air line. ^ Remove air spring upper and lower retaining clips. ^ Compress air spring as necessary to give enough clearance to remove spring. ^ Remove left rear air spring. 11. Use fan to purge gas vapor from under vehicle. 12. Disconnect and plug EVAP canister vapor line. 13. Disconnect EVAP canister electrical connector. 14. Remove canister retaining nuts, then the canister. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > Recalls for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9468 15. Check for outside weld of track bar bracket to frame rail. See Figure 5. NOTE: Perform the following step only if the weld in the previous step is missing. If the weld was present in the previous step, go to Step 17. WARNING POSITION A WELD SHIELD OVER THE FUEL, VAPOR AND BRAKE TUBES IN THE AREA TO BE WELDED. COVER THE SHIELD WITH WET RAGS TO PROTECT IT FROM THE HEAT FROM THE WELDING PROCEDURE. CAUTION Do not use oxy-acetylene torch to weld brackets or frame members. Excessive heat may weaken the metal in the frame members and cause permanent damage. CAUTION As a precaution against damage to electrical components, be sure to disconnect the battery cables before using any welding equipment. Also it is imperative to connect the ground clamp as close to the work area as possible. Perform all welding using Rotunda mig wire feed welder 164-R3667 or equivalent using a 75/25 or 80/20 Argon/CO2 gas mix, and welding wire meeting AWS-E-705 specification. It is essential that the repair welds, particularly on load bearing parts or parts contributing to the strength of the assembly, are equivalent to the original in size, type and strength. 16. To place weld on track bar bracket to frame rail, proceed as follows: ^ Partially lower vehicle. ^ Disconnect positive battery cable from the battery. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > Recalls for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9469 ^ Partially raise vehicle. ^ Clean area shown in Figure 6. ^ Using the above recommended or equivalent mig welder, place weld in location shown in Figure 6. The wire in the mig welder should be .035 inch in diameter to weld this location. 17. Install reinforcing plates as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > Recalls for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9470 ^ Using supplied reinforcing plate mark location in rear flange of track bar bracket for holes to be drilled out. See Figure 7 and 8. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > Recalls for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9471 ^ Using 12 mm drill bit, drill holes in rear flange of track bar bracket. See Figure 9. Make sure to drill straight through the track bar bracket. if holes are drilled on an angle, the inside plate will not line up. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > Recalls for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9472 ^ Install two reinforcing plates, bolts and nuts on rear flange of track bar bracket: one on outside of bracket and one inside of crossmember. Tighten to 81.4 Nm (60 lb/ft) and spray with Super Seal Anti-Corrosion Compound or equivalent. See Figure 10. ^ Repeat step 17 on front flange of track bar bracket. 18. On vehicles equipped with air suspension, install left rear air spring as follows: ^ Position air spring in its mountings. ^ Install air spring upper and lower retaining clips. ^ Connect air spring electrical connector. ^ Connect air spring air line. 19. On vehicles equipped with coil spring suspension, install left rear coil spring as follows: ^ Install coil spring in its mountings. ^ Raise jack to position rear axle in its installed position. ^ Position sway bar on sway bar links, then install retaining bolts. Tighten to 86-114 Nm (65-85 lb/ft). ^ Position both rear shock absorbers on their mounting brackets, then install both lower retaining bolts. Tighten bolts to 86-114 Nm (65-85 lb/ft). ^ Remove hydraulic jack. 20. Position EVAP canister on left frame rail, then install retaining nuts. 21. Connect EVAP canister electrical connector. 22. Unplug and connect canister vapor line. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > Recalls for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9473 23. Install inspection cover on left side frame rail. 24. Install O-rings on both rear hubs. WARNING RETIGHTEN AT 800KM (500 MILES) AFTER ANY WHEEL CHANGE OR ANY TIME THE LUG NUTS ARE LOOSENED. WARNING FAILURE TO RETIGHTEN LUG NUTS AT THE MILEAGE SPECIFIED COULD ALLOW WHEELS TO COME OFF WHILE THE VEHICLE IS IN MOTION, POSSIBLY CAUSING LOSS OF VEHICLE CONTROL AND COLLISION. 25. Install both rear tire and wheel assemblies. Tighten wheel nuts in criss-cross pattern to 115-156 Nm (85-115 lb/ft). 26. Lower vehicle. 27. Install spare tire. 28. Connect battery cable(s), then remove memory saver. 29. On vehicles equipped with air suspension, turn air suspension switch on. Attachment IV - Revised Technical Instructions Announcing revised Technical Instructions for Safety Recall 96560 (Expedition Rear Axle Lower Control Arm/Track Bar Bracket). The following revisions are necessary because a survey of axles inspected by dealers has revealed that most of these axles did not actually need to be replaced. SUPPLEMENTAL TECHNICAL INSTRUCTIONS: 1. Determine the vehicle build date prior to axle inspection. 2. If vehicle build date is August 10, 1996 or later, no axle inspection and/or replacement is required. However, track bar repairs may still be required for the vehicle. Please begin directly at Step # 4 of the original Technical Instructions if build date is August 10, 1996 or later. 3. If vehicle build date is August 9, 1996 or earlier, please proceed with axle inspection as detailed in the original Technical Instructions EXCEPT AS FOLLOWS: a. Remove the axle identification tape (if present) from the right hand axle tube assembly to reveal the date code stamp. b. If you cannot find date code on both axle tube assemblies, call Ford Axle Hot Line at 1 -800-FORD-AXL (1-800-3673-295) before ordering replacement axle assembly to confirm replacement requirements. Please have vehicle VIN and build date available. c. Upon completion of Axle inspection/replacement, proceed to Step # 4 of the original Technical Instructions for Track Bar repair. 4. When attaching the track bar bracket reinforcement kit (Part Number F75Z-5L005-AA), torque the bolts to 68 Nm (50 lb. ft.), NOT 81.4 Nm (60 lb. ft.). 5. Also, when installing the track bar bracket reinforcement kit, the plates should fit flush to the track bar bracket. As required, excess weld material may need to be ground flush to the bracket. If this is required, submit additional time as "Related Damage". Recall/Service Programs Department March 11, 1997 Attachment V - Revised Technical Instr. and Labor Allowances April 7, 1997 Announcing revised Technical Instructions and Labor Allowances for Safety Recall 96S60 (Expedition Rear Axle Lower Control Arm/Track Bar Bracket). 1. REVISED TECHNICAL INSTRUCTIONS: To simplify the inspection process, inspection for welds inside the left track bar bracket is no longer required. Effective immediately, the Track Bar Retaining Kit is to be installed on all affected vehicles. Remember, when installing the Track Bar Retaining Kit, be sure to torque the bolts to 68 Nm (50 lb.ft.) as noted in our 3/11/97 FAX. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > Recalls for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9474 NOTE: Vehicles already reported as INSPECTED only do not have to be returned for the Track Bar Bracket Retaining Kit installation. 2. REVISED LABOR ALLOWANCES: The labor allowances on Attachment II Page 1 of the dealer letter dated February, 1997 have been revised as follows (please annotate your copies appropriately): NOTE: Effective the date of this communication, Labor Operation 96S60A is discontinued because the Track Bar Retaining Bracket Kit is to be installed on all vehicles. Install Track Bar Retaining Plates ONLY (no axle replacement required). (Includes inspection of axle for date codes): NOTE: Also, effective with this communication, Labor Operation 96S60D and Labor Operation 96S60E are discontinued because the Track Bar Retaining Kit is to be installed on all vehicles. Install Track Bar Retaining Plates and new axle assembly. (Includes inspection of axle assembly for date codes): NOTE: Only submit one of the above Labor Operations per vehicle. Be sure to select the correct operation. The labor operations above contain time to re-torque the lug nuts after the 800km (500 mile) interval as recommended in the vehicle Owner Guide. Administrative Allowance - 0.1 Hrs. - Misc. Expense Code "Admin" 3. FOR PREVIOUSLY SUBMITTED CLAIMS: Use the ACESII Online Appeal Procedure to claim the additional time against the original paid repair order that used the previously published labor time. Recall/Service Programs Department April, 1997 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > Recalls for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9475 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > Recalls for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9476 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket Technical Service Bulletin # 96S60 Date: 970201 Recall - Rear Track Arm/Control Arm Bracket SAFETY RECALL 96960 Certain 1997 Model Year Expeditions Built at Michigan Truck Plant - Rear Axle Track Bar Bracket/Lower Control Arm Bracket ^ Dealer Letter ^ Special Recall Parts Announcement ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information - Part 1: Axle Inspection and, if Necessary, Replacement ^ Attachment III ^ Technical Information - Part 2: Track Bar Bracket Inspection/Modification ^ Attachment IV ^ Revised Technical Instructions - March 11, 1997 ^ Attachment V ^ Revised Technical Instructions and Labor Allowances ^ Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9482 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9483 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. Please Note Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,000 per vehicle. Promptly Correct Affected vehicles on the enclosed list. Other eligible vehicles which are brought to your dealership. Dealer-Owner Contact Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Schedule a service date. Regional Contact Advise regional office if: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9484 ^ an owner cannot be contacted. ^ an owner does not make a service date. Claims Submission Enter claims using DWE. See ACESII Manual, Sections 5 and 6. Warranty and Policy Manual See Sections 5 and 6 of the ACESII Manual. Refunds See Section 3-59 of the ACESII Manual. Rental Cars If an inspection reveals that a new axle must be installed, Ford Motor Company will pay for a loaner or rental vehicle, except for fuel, which will be at owner's expense. Enter the word "LOANER" plus the number of days the vehicle was used in the Miscellaneous Expense area. Attachment II - Labor and Parts Information 1997 Model Year Expedition Track Bar Bracket/Lower Control Arm Bracket Labor Allowances NOTE: Only submit one of the above Labor Operations per vehicle. Be sure to select the correct operation. The labor operations above (except Inspection), contain time to re-torque the lug nuts after the 800 km (500 mile) interval as recommended in the vehicle Owner Guide. Parts Requirements Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9485 A small number of "seed stock" parts will be direct shipped to each Ford Division dealer for this recall as follows: 1 part to dealers with 1 to 5 affected vehicles* 3 parts to dealers with 6 to 9 affected vehicles* 5 parts to dealers with 10 or more affected units* *Based on Ford Motor Company Records Shipment of seed stock parts is expected to be completed by February 21, 1997. Order additional parts by calling Renkim (1-800-325-5621). Be prepared to provide the affected VIN number when calling for additional parts. NOTE: If inspection reveals that a new axle assembly is required, call 1-800-325-5621. When calling this number, be prepared to give the following information: NOTE:you will be charged for the axle assembly. ^ Safety Recall 96S60 ^ VIN Number ^ P & A Code ^ Axle Code (See Attachment III for axle codes) ^ Shipping Address ^ Person to whom parts should be sent ^ Telephone Number NOTE: Removed axles must be returned. See instructions below. Axles which are needlessly replaced will be subject to chargeback. Dealer Price For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book Excess Stock Return Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Parts Return You are required to return the removed axle assembly using the shipping container in which the replacement was received. Store the old axle assembly for receipt of the Direct Ship Document that will be on your Overnite Parts register. Clearly mark on the axle assembly Safety Recall 96S60. UPON RECEIPT OF THE DIRECTSHIP DOCUMENT, ship the removed axle assembly, freight prepaid, to: Sterling Axle Plant Attn: Mr. Monzie Edmonds 39000 Mound Road Sterling Heights, Michigan 48301 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9486 Attachment III - Technical Information Part 1: Axle Rear Axle Lower Control Arm Bracket Inspection and/or Track Bar Bracket Modification Affected Vehicles: 1997 Expedition built at the Michigan Truck Plant from March 1, 1996 through October 10,1996 NOTE: This program contains two parts: Part 1: Axle inspection and, if necessary, replacement Part 2: Track bar bracket inspection/modification NOTE: It is most efficient to perform both inspections before proceeding further. Part 1: Axle Inspection and, If Necessary, Replacement 1. On vehicles equipped with air suspension, turn air suspension switch off. Switch is located in the right side kick panel. 2. Raise and support vehicle. 3. Inspect both rear axle tubes for date code stamps. Clean paint or undercoating to locate date code. See Figure 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9487 ^ It date code stamps are present on both rear axle tubes, no service action is required for the rear axle. Go to PART 2. ^ If date code stamps are not on both rear axle tubes, the rear axle must be replaced. Continue on, to order axle. ^ If inspection reveals that the axle must be replaced, check rear axle ID tag for axle ratio code and ring gear diameter, See Figure 2. ^ Cross reference axle ratio code and ring gear diameter in table below to get axle service part number. See Figure 3. ^ Call RENKIM (1-800-325-5621) to order a new axle. When new rear axle is received, proceed to Rear Axle Replacement. Rear Axle Replacement Vehicles Equipped With Rear Air Suspension (See sections for vehicles with rear coil spring suspension) Removal 1. Lower Vehicle 2. Vent air spring air pressure as follows: ^ Turn air suspension switch on. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9488 ^ Turn the ignition to the run position. ^ Connect the NGS tester to the vehicle. ^ Select 1997 4.6L/5.4L Expedition 4WAS module. ^ Select "Air Suspension Control Mode: under "Active Command Modes" menu. ^ Select "VENT REAR" to deflate rear air springs. ^ Turn air suspension switch off. 3. Install memory saver, then disconnect battery negative terminal. 4. Raise and support vehicle. 5. Remove both rear tire and wheel assemblies. 6. Remove driveshaft retaining bolts, then separate driveshaft from companion flange. 7. Wire driveshaft away from the rear axle. 8. Disconnect rear ABS sensor electrical connector, then detach wiring harness from rear axle. 9. On each side of the vehicle, perform the following: ^ Disconnect parking brake cable from parking brake lever. ^ Separate parking brake cable from disc brake adapter. ^ Remove brake caliper retaining bolts, then position brake caliper away from the rear axle. Do not let caliper hang from the brake hose. ^ Remove O-ring from hub, then remove brake rotor from hub. ^ Remove jounce bumper from axle housing. 10. Remove sway bar retainer-to-rear axle mount retaining bolts. Position sway bar away from rear axle. 11. Disconnect load level sensor from rear axle. 12. Position jack stands under rear axle. 13. Lower vehicle enough to release tension on rear axle attaching points (shock absorbers, control arms). 14. Disconnect track bar from rear axle. Position track bar away from rear axle. 15. On each side of the vehicle, perform the following: ^ Remove upper control arm-to-rear axle retaining bolt. Separate control arm from its mounting. ^ Remove lower control arm-to-rear axle retaining bolt. Separate control arm from its mounting. ^ Remove shock absorber-to-rear axle retaining bolt. Separate shock from its mounting. 16. Disconnect axle vent hose from rear axle. 17. Slowly raise the vehicle. Make sure there are not components that will interfere with vehicle separation from the rear axle. 18. Remove rear axle from jack stands. Installation NOTE: New attaching hardware is provided with the replacement axle assembly. Do not use old attaching hardware. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9489 NOTE: Refer to the table to cross-reference circled letters to part description. 1. Position new rear axle on jack stands. 2. Position differential nose on an upward angle using third jack stand. This will allow control arms to clear axle when vehicle is lowered. 3. Lower vehicle over axle. NOTE: Do not tighten retaining nuts at this time. 4. Connect the following components to the rear axle: ^ Air springs ^ Lower control arms (use bolt [A] and nut [C]). ^ Upper control arms (use bolt [A] and nut [B]). ^ Shock absorbers (use bolt [I] and nut [J]). ^ Sway bar retainers (use bolt [E] and nut [D]). ^ Track bar (use bolt [F] and nut [G]). 5. Raise and support vehicle. 6. Position hydraulic jack under rear axle. 7. Raise rear axle until lower control arms are parallel to the ground. NOTE: Tighten both left and right sides of a component before proceeding to the next component. 8. Tighten the following components: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9490 ^ Lower control arm retaining nuts to 128-172 Nm (95-127 lb/ft). ^ Upper control arm retaining nuts to 128-172 Nm (95-127 lb/ft). ^ Shock absorber lower retaining nuts to 88-119 Nm (65-87 lb/ft). ^ Sway bar retainer bolts to 53-72 Nm (39-53 lb/ft). ^ Track bar retaining nut 170-230 Nm (125-169 lb/ft). 9. Connect axle vent hose to the rear axle. 10. Connect the load level sensor to the rear axle. 11. On each side of the vehicle, perform the following: ^ Connect parking brake cable to the parking brake lever. ^ Connect parking brake cable to the disc brake adapter. ^ Install the brake rotor, then the hub O-ring (use O-ring [L]). ^ Position and install the brake caliper. Tighten the retaining bolts to 27 Nm (20 lb/ft). ^ Install jounce bumper onto the rear axle (use screw [H)). Tighten retaining screw to 34-46 Nm (25-33 lb/ft). 12. Route rear ABS sensor wiring harness, then connect rear ABS sensor electrical connector. 13. Align yellow marks on both the driveshaft and companion flange, then install driveshaft retaining bolts (use bolt [K]). Tighten bolts to 88-119 Nm (65-88 lb/ft). WARNING RETIGHTEN AT 800KM (500 MILES) AFTER ANY WHEEL CHANGE OR ANY TIME THE LUG NUTS ARE LOOSENED. WARNING FAILURE TO RETIGHTEN LUG NUTS AT THE MILEAGE SPECIFIED COULD ALLOW WHEELS TO COME OFF WHILE THE VEHICLE IS IN MOTION, POSSIBLY CAUSING LOSS OF VEHICLE CONTROL AND COLLISION. 14. Install both rear tires and wheel assemblies. Tighten wheel nuts in criss-cross pattern to 115-156 Nm (85-115 lb/ft). 15. Lower Vehicle. 16. Turn on air suspension switch. 17. Start and run vehicle. Make sure air suspension system pressurizes the rear air springs. Rear Coil Spring Suspension Vehicles Equipped With Rear Coil Spring Suspension (See previous section for vehicles with rear air suspension) Removal 1. Remove both rear tire and wheel assemblies. 2. Remove driveshaft retaining bolts, then separate driveshaft from companion flange. 3. Wire drive shaft away from the rear axle. 4. Disconnect rear ABS sensor electrical connector, then detach wiring harness from rear axle. 5. On each side of the vehicle, perform the following: ^ Disconnect parking brake cable from parking brake lever. ^ Separate parking brake cable from disc brake adapter. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9491 ^ Remove brake caliper retaining bolts, then position brake caliper away from the rear axle. Do not let caliper hang from the brake hose. ^ Remove O-ring from hub, then remove brake rotor from hub. ^ Remove jounce bumper from axle housing. 6. Remove sway bar retainer-to-rear axle mount retaining bolts. Position sway bar away from rear axle. 7. Position jack stands under rear axle. 8. Lower vehicle enough to release tension on rear axle attaching points (shock absorbers, control arms). 9. Disconnect track bar from rear axle. Position track bar away from rear axle. 10. On each side of the vehicle, perform the following: ^ Remove upper control arm-to-rear axle retaining bolt. Separate control arm from its mounting. ^ Remove lower control arm-to-rear axle retaining bolt. Separate control arm from its mounting. ^ Remove shock absorber-to-rear axle retaining bolt. Separate shock from its mounting. 11. Disconnect axle vent hose from rear axle. 12. Slowly raise the vehicle. Make sure there are no components that will interfere with vehicle separation from the rear axle. 13. Remove both rear coil springs. 14. Remove rear axle from jack stands. Installation NOTE: New attaching hardware is provided with the replacement axle assembly. Do Not use old attaching hardware. NOTE: Refer to the table to cross-reference circle letters to part description. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9492 1. Position new rear axle on jack stands. 2. Position differential nose on an upward angle using third jack stand. This will allow control arms to clear axle when vehicle is lowered. 3. Lower vehicle over axle. NOTE: Do not tighten retaining nuts at this time. 4. Connect the following components to the rear axle: ^ Lower control arms (use bolt [A] and nut [C]). ^ Upper control arms (use bolt [A] and but [B)). 5. Raise and support vehicle. 6. Position hydraulic lack under rear axle. 7. Raise rear axle until lower control arms are parallel to the ground. NOTE: Tighten both left and right sides of a component before proceeding to the next component. 8. Tighten the following components: ^ Lower control arm retaining nuts to 128-172 Nm (95-127 lb/ft). ^ Upper control arm retaining nuts to 128-172 (95-127 lb/ft). 9. Lower the rear axle until axle is hanging freely from hydraulic jack. 10. Install both coil springs. 11. Raise rear axle, then connect the following components to the rear axle: ^ Shock absorbers (use bolt [I] and nut [J]). ^ Sway bar retainers (use bolt [E] and nut [D]). ^ Track bar (use bolt [F] and nut [G]). NOTE: Tighten both left and right sides of a component before proceeding to the next component. 12. Tighten the following components: ^ Shock absorber lower retaining nuts to 88-119 Nm (65-87 lb/ft). ^ Sway bar retainer bolts to 53-72 Nm (39-53 lb/ft). ^ Track bar retaining nut 170-230 Nm (125-169 lb/ft). 13. Connect axle vent hose to the rear axle. 14. On each side of the vehicle, perform the following: ^ Connect parking brake cable to the parking brake lever. ^ Connect parking brake cable to the disc brake adapter. ^ Install the brake rotor, then the hub O-ring (use O-ring [L]). ^ Position and install the brake caliper. Tighten the retaining bolts to 27 Nm (20 lb/ft). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9493 ^ Install jounce bumper onto the rear axle (use screw [H]). Tighten retaining screw to 34-46 Nm (25-33 lb/ft). 15. Route rear ABS sensor wiring harness, then connect rear ABS sensor electrical connector. 16. Align yellow marks on both the driveshaft and companion flange, then install driveshaft retaining bolts (use bolt [K]). Tighten bolts to 88-119 Nm (65-88 lb/ft). WARNING RETIGHTEN AT 800KM (500 MILES) AFTER ANY WHEEL CHANGE OR ANY TIME THE LUG NUTS ARE LOOSENED. WARNING FAILURE TO RETIGHTEN LUG NUTS AT THE MILEAGE SPECIFIED COULD ALLOW WHEELS TO COME OFF WHILE THE VEHICLE IS IN MOTION, POSSIBLY CAUSING LOSS OF VEHICLE CONTROL AND COLLISION. 17. Install both rear tires and wheel assemblies. Tighten wheel nuts in criss-cross pattern to 115-156 Nm (85-115 lb/ft). 18. Lower vehicle. Attachment III - Technical Information - Part 2: Bar Bracket Rear Axle Lower Control Arm Bracket Inspection and/or Track Bar Bracket Modification Affected Vehicles: 1997 Expedition built at the Michigan Truck Plant from March 1, 1996 through October 10, 1996 NOTE: This program contains two parts: Part 1: Axle inspection and, if necessary, replacement Part 2: Track bar bracket inspection/modification Inspection Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9494 1. Inspect for welds on inside of left track bar bracket. See Figure 4. ^ If welds are present, no track bar bracket service action is required for the vehicle. Lower vehicle and turn air suspension switch on, if equipped. Return vehicle to the customer unless axle is to be replaced. ^ If welds are not present, proceed to Track Bar Bracket Modification. In the rare case where the bracket has been separated from the frame, call Renkim at 1-800-325-5621. Track Bar Bracket Modification 1. Lower vehicle. 2. Remove spare tire assembly. 3. On vehicles equipped with air suspension, vent air spring air pressure as follows: ^ Turn air suspension switch on. ^ Turn the ignition to the run position. ^ Connect the NGS tester to the vehicle. ^ Select 1997 4.6L/5.4L Expedition 4WAS module. ^ Select "Air Suspension Control Mode: under "Active Command Modes" menu. ^ Select "VENT REAR" to deflate rear air springs. ^ Turn air suspension switch off. 4. Install memory saver, then disconnect battery negative cable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9495 5. Raise and support vehicle. 6. Remove both rear tire and wheel assemblies. 7. Remove 0-rings from both rear hubs. 8. Remove inspection cover from left side frame rail above the rear axle. 9. On vehicles equipped with coil spring suspension, remove left rear coil spring as follows: ^ Place hydraulic jack under axle housing. ^ Raise jack slightly to release tension on rear axle components. ^ Remove both rear shock absorber lower mounting bolts. ^ Remove both sway bar to sway bar link retaining bolts. Position sway bar away from links. ^ Lower jack enough to release spring tension. ^ Remove left rear spring. 10. On vehicles equipped with air suspension, remove left rear air spring as follows: ^ Disconnect air spring electrical connector. ^ Disconnect air spring air line. ^ Remove air spring upper and lower retaining clips. ^ Compress air spring as necessary to give enough clearance to remove spring. ^ Remove left rear air spring. 11. Use fan to purge gas vapor from under vehicle. 12. Disconnect and plug EVAP canister vapor line. 13. Disconnect EVAP canister electrical connector. 14. Remove canister retaining nuts, then the canister. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9496 15. Check for outside weld of track bar bracket to frame rail. See Figure 5. NOTE: Perform the following step only if the weld in the previous step is missing. If the weld was present in the previous step, go to Step 17. WARNING POSITION A WELD SHIELD OVER THE FUEL, VAPOR AND BRAKE TUBES IN THE AREA TO BE WELDED. COVER THE SHIELD WITH WET RAGS TO PROTECT IT FROM THE HEAT FROM THE WELDING PROCEDURE. CAUTION Do not use oxy-acetylene torch to weld brackets or frame members. Excessive heat may weaken the metal in the frame members and cause permanent damage. CAUTION As a precaution against damage to electrical components, be sure to disconnect the battery cables before using any welding equipment. Also it is imperative to connect the ground clamp as close to the work area as possible. Perform all welding using Rotunda mig wire feed welder 164-R3667 or equivalent using a 75/25 or 80/20 Argon/CO2 gas mix, and welding wire meeting AWS-E-705 specification. It is essential that the repair welds, particularly on load bearing parts or parts contributing to the strength of the assembly, are equivalent to the original in size, type and strength. 16. To place weld on track bar bracket to frame rail, proceed as follows: ^ Partially lower vehicle. ^ Disconnect positive battery cable from the battery. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9497 ^ Partially raise vehicle. ^ Clean area shown in Figure 6. ^ Using the above recommended or equivalent mig welder, place weld in location shown in Figure 6. The wire in the mig welder should be .035 inch in diameter to weld this location. 17. Install reinforcing plates as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9498 ^ Using supplied reinforcing plate mark location in rear flange of track bar bracket for holes to be drilled out. See Figure 7 and 8. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9499 ^ Using 12 mm drill bit, drill holes in rear flange of track bar bracket. See Figure 9. Make sure to drill straight through the track bar bracket. if holes are drilled on an angle, the inside plate will not line up. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9500 ^ Install two reinforcing plates, bolts and nuts on rear flange of track bar bracket: one on outside of bracket and one inside of crossmember. Tighten to 81.4 Nm (60 lb/ft) and spray with Super Seal Anti-Corrosion Compound or equivalent. See Figure 10. ^ Repeat step 17 on front flange of track bar bracket. 18. On vehicles equipped with air suspension, install left rear air spring as follows: ^ Position air spring in its mountings. ^ Install air spring upper and lower retaining clips. ^ Connect air spring electrical connector. ^ Connect air spring air line. 19. On vehicles equipped with coil spring suspension, install left rear coil spring as follows: ^ Install coil spring in its mountings. ^ Raise jack to position rear axle in its installed position. ^ Position sway bar on sway bar links, then install retaining bolts. Tighten to 86-114 Nm (65-85 lb/ft). ^ Position both rear shock absorbers on their mounting brackets, then install both lower retaining bolts. Tighten bolts to 86-114 Nm (65-85 lb/ft). ^ Remove hydraulic jack. 20. Position EVAP canister on left frame rail, then install retaining nuts. 21. Connect EVAP canister electrical connector. 22. Unplug and connect canister vapor line. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9501 23. Install inspection cover on left side frame rail. 24. Install O-rings on both rear hubs. WARNING RETIGHTEN AT 800KM (500 MILES) AFTER ANY WHEEL CHANGE OR ANY TIME THE LUG NUTS ARE LOOSENED. WARNING FAILURE TO RETIGHTEN LUG NUTS AT THE MILEAGE SPECIFIED COULD ALLOW WHEELS TO COME OFF WHILE THE VEHICLE IS IN MOTION, POSSIBLY CAUSING LOSS OF VEHICLE CONTROL AND COLLISION. 25. Install both rear tire and wheel assemblies. Tighten wheel nuts in criss-cross pattern to 115-156 Nm (85-115 lb/ft). 26. Lower vehicle. 27. Install spare tire. 28. Connect battery cable(s), then remove memory saver. 29. On vehicles equipped with air suspension, turn air suspension switch on. Attachment IV - Revised Technical Instructions Announcing revised Technical Instructions for Safety Recall 96560 (Expedition Rear Axle Lower Control Arm/Track Bar Bracket). The following revisions are necessary because a survey of axles inspected by dealers has revealed that most of these axles did not actually need to be replaced. SUPPLEMENTAL TECHNICAL INSTRUCTIONS: 1. Determine the vehicle build date prior to axle inspection. 2. If vehicle build date is August 10, 1996 or later, no axle inspection and/or replacement is required. However, track bar repairs may still be required for the vehicle. Please begin directly at Step # 4 of the original Technical Instructions if build date is August 10, 1996 or later. 3. If vehicle build date is August 9, 1996 or earlier, please proceed with axle inspection as detailed in the original Technical Instructions EXCEPT AS FOLLOWS: a. Remove the axle identification tape (if present) from the right hand axle tube assembly to reveal the date code stamp. b. If you cannot find date code on both axle tube assemblies, call Ford Axle Hot Line at 1 -800-FORD-AXL (1-800-3673-295) before ordering replacement axle assembly to confirm replacement requirements. Please have vehicle VIN and build date available. c. Upon completion of Axle inspection/replacement, proceed to Step # 4 of the original Technical Instructions for Track Bar repair. 4. When attaching the track bar bracket reinforcement kit (Part Number F75Z-5L005-AA), torque the bolts to 68 Nm (50 lb. ft.), NOT 81.4 Nm (60 lb. ft.). 5. Also, when installing the track bar bracket reinforcement kit, the plates should fit flush to the track bar bracket. As required, excess weld material may need to be ground flush to the bracket. If this is required, submit additional time as "Related Damage". Recall/Service Programs Department March 11, 1997 Attachment V - Revised Technical Instr. and Labor Allowances April 7, 1997 Announcing revised Technical Instructions and Labor Allowances for Safety Recall 96S60 (Expedition Rear Axle Lower Control Arm/Track Bar Bracket). 1. REVISED TECHNICAL INSTRUCTIONS: To simplify the inspection process, inspection for welds inside the left track bar bracket is no longer required. Effective immediately, the Track Bar Retaining Kit is to be installed on all affected vehicles. Remember, when installing the Track Bar Retaining Kit, be sure to torque the bolts to 68 Nm (50 lb.ft.) as noted in our 3/11/97 FAX. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9502 NOTE: Vehicles already reported as INSPECTED only do not have to be returned for the Track Bar Bracket Retaining Kit installation. 2. REVISED LABOR ALLOWANCES: The labor allowances on Attachment II Page 1 of the dealer letter dated February, 1997 have been revised as follows (please annotate your copies appropriately): NOTE: Effective the date of this communication, Labor Operation 96S60A is discontinued because the Track Bar Retaining Bracket Kit is to be installed on all vehicles. Install Track Bar Retaining Plates ONLY (no axle replacement required). (Includes inspection of axle for date codes): NOTE: Also, effective with this communication, Labor Operation 96S60D and Labor Operation 96S60E are discontinued because the Track Bar Retaining Kit is to be installed on all vehicles. Install Track Bar Retaining Plates and new axle assembly. (Includes inspection of axle assembly for date codes): NOTE: Only submit one of the above Labor Operations per vehicle. Be sure to select the correct operation. The labor operations above contain time to re-torque the lug nuts after the 800km (500 mile) interval as recommended in the vehicle Owner Guide. Administrative Allowance - 0.1 Hrs. - Misc. Expense Code "Admin" 3. FOR PREVIOUSLY SUBMITTED CLAIMS: Use the ACESII Online Appeal Procedure to claim the additional time against the original paid repair order that used the previously published labor time. Recall/Service Programs Department April, 1997 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9503 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Traction Bar > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Traction Bar: > 96S60 > Feb > 97 > Recall - Rear Track Arm/Control Arm Bracket > Page 9504 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Specifications Trailing Arm: Specifications Trackbar to Rear Axle Bolt .................................................................................................................................................... 170-230 Nm (125-170 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9512 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9513 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9514 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9515 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9516 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9517 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9518 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9519 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9520 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9521 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9522 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9523 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9524 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9525 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9526 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9527 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9528 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9529 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9530 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9531 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9532 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9533 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9534 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9535 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9536 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9537 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9538 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9539 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9540 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9541 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9542 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9543 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9544 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9545 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9546 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9547 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9548 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9549 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9550 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9551 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9552 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9553 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9554 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9555 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9556 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9557 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9558 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9559 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9560 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9561 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9562 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9563 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9564 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9565 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9566 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9567 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9568 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9569 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9570 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9571 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9572 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9573 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9574 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9575 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9576 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9577 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9578 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9579 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9580 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9581 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9582 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9583 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9584 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9585 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9586 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9587 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9588 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9589 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9590 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9591 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9592 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9593 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9594 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9595 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9596 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9597 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9598 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9599 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9600 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9601 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9602 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9603 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9604 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9605 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9606 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Page 9607 Wheel Bearing: Specifications ^ Lubricate the new rear axle bearing. Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. ^ Lubricate the lip of the new axle shaft oil seal. Use Premium Long-Life Grease XG-1-C or XG-1-K or equivalent meeting Ford specification ESA-M1C75-B. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications TORQUE SPECIFICATIONS Front Axle Hub Nut ........................................................................................................................................................... 255-345 Nm (188-254 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair Front Jacking Points 1. The jacking point is a raised boss located on the front suspension lower arm. WARNING: The electrical power to the air suspension system must be shut down prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning OFF the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. WARNING: DO NOT run the engine when jacking the vehicle. The wheels contacting the ground could cause the vehicle to move. WARNING: Support the vehicle prior to performing any procedure requiring the vehicle to be lifted off of the ground. WARNING: Make sure jack and jack stands are properly located to prevent the vehicle from falling. WARNING: Wheel chocks should be used to prevent the vehicle from rolling and falling off the jack. Rear Jacking Points 1. The jacking point is a bracket welded to the frame. WARNING: The electrical power to the air suspension system must be shut down prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning OFF the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. WARNING: DO NOT run the engine when jacking the vehicle. The wheels contacting the ground could cause the vehicle to move. WARNING: Support the vehicle prior to performing any procedure requiring the vehicle to be lifted off of the ground. WARNING: Make sure jack and jack stands are properly located to prevent the vehicle from falling. WARNING: Wheel chocks should be used to prevent the vehicle from rolling and falling off the jack. Twin Post Hoist Lifting Points Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Page 9616 1. Locate front hoist adapters and rear hoist adapters (top of frame arc) as indicated. WARNING: The electrical power to the air suspension system must be shut down prior to hoisting, jacking, or towing an air suspension vehicle. This can be accomplished by turning OFF the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. CAUTION: Damage to suspension, exhaust, and steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Drive on Hoist Lifting Points 1. Vehicle is supported by tires and suspension components. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Specifications Spare Tire: Specifications Spare Tire Carrier Bolts ....................................................................................................................... .......................................... 23-32 Nm (17-23 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Specifications > Page 9621 Spare Tire: Service and Repair REMOVAL 1. Lower the spare tire. (1) Insert the drive end of the jack handle through the opening left of the license plate. (2) Turn the jack handle until slack is present in the cable. 2. Remove the spare tire. (1) Slide the retainer through the center of the spare tire assembly. (2) Remove the spare tire assembly. WARNING: THEE ELECTRICAL POWER TO THEE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 3. Raise and support the vehicle. 4. Remove the spare tire carrier. (1) Remove the two bolts. (2) Turn the spare tire carrier to disengage the spare tire carrier from the tabs and remove the spare tire carrier. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Specifications > Page 9622 INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9627 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9628 Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9629 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9630 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9631 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9632 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9633 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9634 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9635 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9636 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9637 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9638 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9639 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9640 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9641 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9642 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9643 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9644 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9645 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9646 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9647 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9648 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9649 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9650 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9651 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9652 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9653 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9654 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9655 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9656 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9657 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9658 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9659 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9660 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9661 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9662 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9663 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9664 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9665 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9666 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9667 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9668 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9669 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9670 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9671 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9672 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9673 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9674 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9675 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9676 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9677 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9678 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9679 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9680 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9681 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9682 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9683 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9684 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9685 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9686 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9687 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9688 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9689 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9690 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9691 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9692 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9693 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9694 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9695 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9696 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9697 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9698 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9699 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9700 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9701 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9702 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9703 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9704 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9705 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9706 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9707 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9708 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9709 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9710 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9711 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9712 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9713 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9714 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9715 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9716 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9717 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9718 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9719 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9720 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9721 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9722 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 9723 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 9724 Wheels: Specifications GENERAL Cast Aluminum .................................................................................................................................... .................................................................. 17x7.5J Steel .................................................................... ...................................................................................................................................................... 16x7J Styled Aluminum ....................................................................................................................... ............................................................................... 16x7J Styled Argent Steel ................................... .............................................................................................................................................................. .. 16x7J Max Balance Weight (Total of Inner & Outer Flanges) ................................................................................................................................. 170 g (6 oz) Wheel Offset ........................................................................................................................................ ................................................................... 14 mm Wheel Rim Runout (Radial or Lateral) ................................................................................................................................................ 1.12 mm (0.044 in) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Wheels: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 9727 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 9728 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 9729 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 9730 Wheels: Component Tests and General Diagnostics Runout TEST DESCRIPTION Excessive radial and lateral runout of a wheel and tire assembly can cause roughness, vibration, wheel tramp, tire wear, and steering wheel tremor. Before checking runout and to avoid false readings caused by temporary flat spots in the tires, check runout only after the vehicle has been driven far enough to warm tires. The extent of the runout is measured with Radial Runout Gauge. All measurements are made on the vehicle with the tires inflated to recommended inflation pressures and with the front wheel bearings adjusted to specifications. TIRE RUNOUT Use Radial Runout Gauge to measure (A) radial runout of the tire at the center and outside ribs of the tread face. Mark the high points of radial runout for future reference. Radial runout should not exceed specifications. WHEEL RUNOUT Measure (B) radial and (C) lateral wheel runout at the positions shown in the illustration. Runout should not exceed specifications. Wheel Centering 0-Ring Seal The front hub and rear axle wheel pilots are fitted with rubber O-rings which help center the wheels. Remove the O-ring and clean the machined groove and clean and lubricate the O-ring if required. Replace the O-ring if damaged. O-rings should be pulled on (not pushed) so that the yellow paint identification stripe is visible after installation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Testing and Inspection > Page 9731 Wheels: Service and Repair REMOVAL 1. Loosen the lug nuts. (1) Remove the center cap. (2) With the weight of the vehicle on the wheels, loosen the lug nuts. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and wheel bearings. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MA Y RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Raise and support the vehicle. 3. Remove the wheel and tire assembly. (1) Remove the lug nuts. (2) Remove the wheel and tire assembly. INSTALLATION 1. Clean the wheel hub mounting surface. WARNING: WHEN A WHEEL IS INSTALLED, ALWAYS REMOVE ANY CORROSION, DIRT OR FOREIGN MATERIAL PRESENT ON THE MOUNTING SURFACES OF THE WHEEL OR THE SURFACE OF THE WHEEL HUB, BRAKE DRUM OR BRAKE ROTOR THAT CONTACTS THE WHEEL. INSTALLING WHEELS WITHOUT PROPER METAL TO METAL CONTACT AT THE WHEEL MOUNTING SURFACES CAN CAUSE THE LUG NUTS TO LOOSEN AND THE WHEEL TO COME OFF WHILE THE VEHICLE IS IN MOTION, CAUSING LOSS OF CONTROL. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Testing and Inspection > Page 9732 2. Install the tire and wheel assembly. (1) Position the tire and wheel assembly (2) Install the lug nuts and lower the vehicle. (3) Tighten in sequence the lug nuts. (4) Install the wheel cover. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9737 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9738 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9739 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9740 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9741 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9742 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9743 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9744 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9745 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9746 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9747 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9748 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9749 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9750 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9751 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9752 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9753 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9754 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9755 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9756 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9757 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9758 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9759 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9760 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9761 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9762 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9763 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9764 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9765 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9766 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9767 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9768 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9769 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9770 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9771 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9772 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9773 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9774 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9775 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9776 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9777 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9778 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9779 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9780 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9781 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9782 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9783 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9784 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9785 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9786 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9787 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9788 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9789 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9790 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9791 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9792 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9793 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9794 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9795 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9796 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9797 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9798 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9799 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9800 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9801 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9802 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9803 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9804 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9805 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9806 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9807 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9808 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9809 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9810 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9811 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9812 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9813 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9814 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9815 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9816 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9817 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9818 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9819 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9820 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9821 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9822 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9823 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9824 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9825 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9826 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9827 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9828 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9829 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9830 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 9831 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Page 9832 Wheel Bearing: Specifications ^ Lubricate the new rear axle bearing. Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. ^ Lubricate the lip of the new axle shaft oil seal. Use Premium Long-Life Grease XG-1-C or XG-1-K or equivalent meeting Ford specification ESA-M1C75-B. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications TORQUE SPECIFICATIONS Front Axle Hub Nut ........................................................................................................................................................... 255-345 Nm (188-254 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Recalls: > NHTSA98V095000 > May > 98 > Recall 98V095000: Lug Nut Replacement Wheel Fastener: Recalls Recall 98V095000: Lug Nut Replacement Year: 1997, 1998 Make: LINCOLN TRUCK, FORD TRUCK Model: NAVIGATOR, EXPEDITION, F150, F250 Year of Recall: '98 Type of Report: Vehicle Potential Number of Units Affected: 1520000 Summary: Vehicle Description: Multi-purpose vehicles and light duty pickup trucks. The lug nuts on these vehicles may not create sufficient clamp load allowing wheel movement in relation to the hub/rotor mounting surface. This can result in the loosening of lug nuts, stud fatigue failure, and the potential for a wheel separation from the vehicle, increasing the risk of a vehicle crash. Dealers will inspect the wheel studs and replace the wheel lug nuts. Owner notification is expected to begin July 20, 1998. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > NHTSA98V095000 > May > 98 > Recall 98V095000: Lug Nut Replacement Wheel Fastener: All Technical Service Bulletins Recall 98V095000: Lug Nut Replacement Year: 1997, 1998 Make: LINCOLN TRUCK, FORD TRUCK Model: NAVIGATOR, EXPEDITION, F150, F250 Year of Recall: '98 Type of Report: Vehicle Potential Number of Units Affected: 1520000 Summary: Vehicle Description: Multi-purpose vehicles and light duty pickup trucks. The lug nuts on these vehicles may not create sufficient clamp load allowing wheel movement in relation to the hub/rotor mounting surface. This can result in the loosening of lug nuts, stud fatigue failure, and the potential for a wheel separation from the vehicle, increasing the risk of a vehicle crash. Dealers will inspect the wheel studs and replace the wheel lug nuts. Owner notification is expected to begin July 20, 1998. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure Wheel Fastener: All Technical Service Bulletins Lug Nuts - Proper Installation/Torqueing Procedure Article No. 98-5A-4 ^ BRAKES - PREVENTING BRAKE VIBRATION - SERVICE TIP ^ WHEELS - PROPER LUG TORQUE PROCEDURES - SERVICE TIP FORD: 1972-97 THUNDERBIRD 1976-86 LTD 1976-97 MUSTANG 1981-97 CROWN VICTORIA 1982-88 EXP 1982-98 ESCORT 1984-94 TEMPO 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1979-83 MONARCH, ZEPHYR 1979-97 COUGAR 1980-83 MARK VI 1980-98 CONTINENTAL, TOWN CAR 1981-86 LYNX 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-97 SABLE 1987-89 TRACER 1987-97 GRAND MARQUIS 1991-94 CAPRI 1991-97 TRACER 1993-98 MARK VIII 1995-98 MYSTIQUE LIGHT TRUCK: 1979-96 BRONCO 1979-97 ECONOLINE, F-150-350 SERIES 1984-90 BRONCO II 1984-97 RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-98 WINDSTAR 1997 EXPEDITION 1998 NAVIGATOR ISSUE: The use of air impact tools to tighten wheel lug nuts can lead to overtightened and/or unevenly tightened wheel lug nuts. Air impact tools typically used for wheel lug nut removal and installation can generate up to 475 N.m (350 lb-ft) of torque. Overtightened and/or unevenly torqued wheel lug nuts may cause: ^ Brake vibration ^ Distortion of the wheel hub ^ Distortion of the brake rotor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure > Page 9854 ^ Brake rotor runout ^ Damage to the wheel ^ Damage to the wheel nuts and studs ACTION: All wheel lug nuts should only be tightened to specification using a torque wrench or by using the Rotunda ACCUTORO 164-R0314 or equivalent on a 1/2" drive air impact tool. The "ACCUTORO" lug nut sockets limit the torque of the air impact tool, preventing overtightening or uneven tightening of the wheel lug nuts. The torque limiting devices (regulators) on air impact tools will not reduce the output torque enough to prevent overtightening of the wheel lug nuts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure > Page 9855 NOTE: REFER TO THE APPROPRIATE SERVICE MANUAL OR THE CHART IN FIGURE 1 FOR THE CORRECT WHEEL LUG NUT TORQUE SPECIFICATION. THE CHART IN FIGURE 1 ALSO PROVIDES THE CORRECT "ACCUTORO" LUG NUT SOCKET TO USE. The "ACCUTORO" socket is intended for lug nut installation, not removal. When using the "ACCUTORO" socket, the output torque of the air impact tool must be set to 217-339 N.m (160-250 lb-ft), usually this will be the lowest setting on the air impact tool. The "ACCUTORO" lug nut sockets are available through Rotunda Equipment. The four-piece set (164-R0314) fits most Ford Motor Company cars and light trucks. The tool set consists of four (4) lug nut sockets and a storage case. The set can be ordered by calling Rotunda Equipment at 1-800-ROT-UNDA (768-8632). CAUTION: AIR IMPACT TOOLS SHOULD NOT BE USED TO TIGHTEN WHEEL LUG NUTS UNLESS THE "ACCUTORO" LUG NUT SOCKET OF THE CORRECT SPECIFICATION IS USED. NOTE: DO NOT USE AIR IMPACT TOOLS ON LOCKING WHEEL LUG NUTS. THEY ARE TO BE HAND-TORQUED ONLY. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-17-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 303000, 306000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure Wheel Fastener: All Technical Service Bulletins Lug Nuts - Proper Installation/Torqueing Procedure Article No. 98-5A-4 ^ BRAKES - PREVENTING BRAKE VIBRATION - SERVICE TIP ^ WHEELS - PROPER LUG TORQUE PROCEDURES - SERVICE TIP FORD: 1972-97 THUNDERBIRD 1976-86 LTD 1976-97 MUSTANG 1981-97 CROWN VICTORIA 1982-88 EXP 1982-98 ESCORT 1984-94 TEMPO 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1979-83 MONARCH, ZEPHYR 1979-97 COUGAR 1980-83 MARK VI 1980-98 CONTINENTAL, TOWN CAR 1981-86 LYNX 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-97 SABLE 1987-89 TRACER 1987-97 GRAND MARQUIS 1991-94 CAPRI 1991-97 TRACER 1993-98 MARK VIII 1995-98 MYSTIQUE LIGHT TRUCK: 1979-96 BRONCO 1979-97 ECONOLINE, F-150-350 SERIES 1984-90 BRONCO II 1984-97 RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-98 WINDSTAR 1997 EXPEDITION 1998 NAVIGATOR ISSUE: The use of air impact tools to tighten wheel lug nuts can lead to overtightened and/or unevenly tightened wheel lug nuts. Air impact tools typically used for wheel lug nut removal and installation can generate up to 475 N.m (350 lb-ft) of torque. Overtightened and/or unevenly torqued wheel lug nuts may cause: ^ Brake vibration ^ Distortion of the wheel hub ^ Distortion of the brake rotor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure > Page 9861 ^ Brake rotor runout ^ Damage to the wheel ^ Damage to the wheel nuts and studs ACTION: All wheel lug nuts should only be tightened to specification using a torque wrench or by using the Rotunda ACCUTORO 164-R0314 or equivalent on a 1/2" drive air impact tool. The "ACCUTORO" lug nut sockets limit the torque of the air impact tool, preventing overtightening or uneven tightening of the wheel lug nuts. The torque limiting devices (regulators) on air impact tools will not reduce the output torque enough to prevent overtightening of the wheel lug nuts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure > Page 9862 NOTE: REFER TO THE APPROPRIATE SERVICE MANUAL OR THE CHART IN FIGURE 1 FOR THE CORRECT WHEEL LUG NUT TORQUE SPECIFICATION. THE CHART IN FIGURE 1 ALSO PROVIDES THE CORRECT "ACCUTORO" LUG NUT SOCKET TO USE. The "ACCUTORO" socket is intended for lug nut installation, not removal. When using the "ACCUTORO" socket, the output torque of the air impact tool must be set to 217-339 N.m (160-250 lb-ft), usually this will be the lowest setting on the air impact tool. The "ACCUTORO" lug nut sockets are available through Rotunda Equipment. The four-piece set (164-R0314) fits most Ford Motor Company cars and light trucks. The tool set consists of four (4) lug nut sockets and a storage case. The set can be ordered by calling Rotunda Equipment at 1-800-ROT-UNDA (768-8632). CAUTION: AIR IMPACT TOOLS SHOULD NOT BE USED TO TIGHTEN WHEEL LUG NUTS UNLESS THE "ACCUTORO" LUG NUT SOCKET OF THE CORRECT SPECIFICATION IS USED. NOTE: DO NOT USE AIR IMPACT TOOLS ON LOCKING WHEEL LUG NUTS. THEY ARE TO BE HAND-TORQUED ONLY. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-17-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 303000, 306000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Fastener Wheel Fastener: Specifications Wheel Fastener TORQUE Lug Nuts: 113-153 Nm (83-112 ft. lbs.) GENERAL Lug Nuts (metric): M12 x 1.75 - 19 mm hex Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Fastener > Page 9865 Wheel Fastener: Specifications Wheel Stud Wheel Stud (metric) ............................................................................................................................. ........................................... M12 x 1.75 - 19 mm hex Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 9866 Wheel Fastener: Service and Repair REMOVAL 1. Remove the wheel hub. 2. Remove the damaged lug bolts. CAUTION: Do not press on bearing when removing or installing lug bolts. INSTALLATION NOTE: The wheel bearing and hub are replaced as an assembly. 1. Install the new lug bolts. CAUTION: Do not press on bearing when removing or installing lug bolts. 2. Install the wheel hub. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications Accumulator HVAC: Specifications Suction Accumulator Bracket Bolt ............................................................................................................................................. 9-11.2 N.m (80-100 Lb/In) Suction Accumulator Fitting ................................................................................................................................................... 25.5-34.5 N.m (19-25 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 9871 Accumulator HVAC: Description and Operation NOTE: Replacement of the suction accumulator/drier is necessary if there is moisture in the system, the system is open for an extended amount of time or any time a major component is replaced. Major components include: ^ A/C compressor. ^ A/C condenser core. ^ The A/C evaporator core. ^ Refrigerant hose/line. An A/C evaporator core orifice or an O-ring seal are not considered major components. The suction accumulator/drier is mounted on the A/C accumulator bracket to the RH side of the instrument panel in the engine compartment. The inlet tube of the suction accumulator/drier is attached to the A/C evaporator core outlet tube. The outlet tube of the suction accumulator/drier attaches to the A/C manifold and tube. A desiccant bag located inside the suction accumulator/drier absorbs any moisture in the refrigerant system. After entering the inlet of the suction accumulator/drier, heavier oil-laden and liquid refrigerant contacts an internally mounted dome and drips down onto the bottom of the canister. A small diameter oil bleed hole in the bottom of the vapor return tube allows the accumulated refrigerant and oil mixture to re-enter the compressor suction line at a controlled rate. A fine-meshed screened filter fits tightly around the bottom of the vapor return tube to filter out refrigerant system contaminant particles. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 9872 Accumulator HVAC: Service and Repair Spring Lock Coupling Disconnect Tool Set Spring Lock Coupling Disconnect Tool (5/8 Inch) Spring Lock Coupling Spring Lock Coupling Special Tools REMOVAL CAUTION: Replacement of the suction accumulator/drier is necessary any time a major component of the refrigerant system is replaced. Failure to replace the suction accumulator/drier will expose the refrigerant system to excessive moisture accumulation. The suction accumulator/drier should also be replaced if the suction accumulator/drier is perforated, if the refrigerant system has been opened to the atmosphere for other than a minor repair or there is evidence of moisture in the system (internal corrosion of metal refrigerant lines or refrigerant oil is thick and dark). NOTE: Compressor oil from vehicles equipped with an FS-10 A/C compressor may have a darker color while maintaining a normal oil viscosity. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 9873 1. Disconnect the battery ground cable. 2. Recover the refrigerant from the system. See: Service and Repair/Refrigerant Recovery 3. Disconnect the A/C cycling pressure switch electrical connector. 4. Disconnect the manifold and tube fitting. 5. Remove the accumulator bracket clamping bolt. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 9874 6. Fit Spring Lock Coupling Disconnect Tool to the condenser lines so that the spring lock coupling tool can enter the cage opening to release the A/C tube lock coupling spring. 7. Push the tool into the cage opening to release the female fitting from the A/C tube lock coupling spring. 8. Pull the spring lock coupling fittings apart. 9. Remove the suction accumulator/drier. 10. Drain the oil from the removed suction accumulator/drier into a suitable measuring container. It may he necessary to drill one or two 12.7 mm (1/2 inch) holes in the bottom of the old suction accumulator/drier to make sure that all the oil has drained out. INSTALLATION 1. Add refrigerant oil. ^ Use Motorcraft YN-12b Refrigerant Oil F2AZ-19577-AC or equivalent meeting Ford specification WSH-M1C231-B. NOTE: Add the same amount of clean new refrigerant oil that was removed, plus 59 ml (two fluid ounces) to the new suction accumulator/drier. Use only the oil specified for the vehicle being serviced. 2. Transfer the A/C cycling pressure switch to the new suction accumulator/drier. 3. Install new O-rings. NOTE: Lubricate new O-ring seals liberally with clean Motorcraft YN-12b Refrigerant Oil F2AZ-19577-AC or equivalent meeting Ford Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 9875 specification WSH-M1C231-B. 4. Install the suction accumulator/drier. 5. Install the accumulator bracket clamping bolt. 6. Check for a missing or damaged A/C tube lock coupling spring. A damaged spring can be removed with a small hooked wire. Install a new spring if the old one is damaged or missing. 7. Clean the fittings. 8. On the (A) female spring lock coupling, check the inside of each fitting for scratches, corrosion or debris from deteriorated (B) O-rings. ^ Remove any surface residue from the inside of the coupling by polishing with 400-grit emery cloth (or equivalent). Polish the surface by using a twisting motion so that any scratches made will not cross the O-ring sealing surface. Finish polishing with 600-grit emery cloth or equivalent. Remove all polishing residue from the fitting with a lint free cloth. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 9876 9. Use the (A) plastic O-ring tool supplied in O-ring kit or equivalent to remove the (B) O-ring seals from the male fitting. NOTE: Do not use metal O-ring tools. They can cause axial scratches across the O-ring grooves, resulting in refrigerant leakage. 10. Install the O-ring seals. Lubricate new O-ring seals. ^ Use Motorcraft Refrigerant Oil YN-12b, F2AZ-19577-AC or equivalent meeting Ford specification WSH-M1C231-B to lubricate seals. NOTE: Use only specified O-ring seals. Use of any O-ring seal other than the one specified may allow the connection to leak intermittently during vehicle operation. 11. Lubricate the male fitting and O-ring seals, and the inside of the female fitting. ^ Use Motorcraft Refrigerant Oil YN-12b, F2AZ-19577-AC or equivalent meeting Ford specification WSH-M1C231-B. 12. Install a plastic indicator ring into cage opening if an indicator ring is to be used. 13. Fit the female fitting to the male fitting and push with a twisting motion until the garter spring snaps over the flared end of the female fitting. NOTE: If a plastic indicator ring is used, it will snap out of the cage opening when the coupling is connected to indicate engagement. 14. If an indicator ring is not used, check the coupling engagement by making sure the garter spring is over the flared end of the fitting. 15. Connect the manifold tube fitting. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 9877 16. Connect the A/C cycling pressure switch electrical connector. 17. Connect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. 18. Leak test the system. 19. Evacuate and charge the system. See: Service and Repair/Evacuation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 9878 Accumulator HVAC: Tools and Equipment Spring Lock Coupling Disconnect Tool Set Spring Lock Coupling Disconnect Tool (5/8 Inch) Spring Lock Coupling Spring Lock Coupling Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Air Door Actuator / Motor: > 97-19-19 > Sep > 97 > A/C No Airflow From Floor Vents Air Door Actuator / Motor: Customer Interest A/C - No Airflow From Floor Vents Article No. 97-19-19 09/15/97 ^ AIR CONDITIONING - NO AIRFLOW FROM FLOOR HEATER - NO AIRFLOW FROM FLOOR LIGHT TRUCK: 1997 EXPEDITION, F-150-350 SERIES ISSUE: Airflow from the air conditioner or heater will not switch to FLOOR mode on some vehicles. This may be due to the panel/floor door vacuum motor linkage being disconnected from the door pivot. ACTION: Replace the vacuum motor assembly. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify concern. 2. Remove and replace panel/floor door Vacuum Motor (F75Z-18A318-AA). Refer to the appropriate Service Manual for removal procedure. Make sure linkage is fully engaged in door pivot. 3. Verify proper heating system operation. PART NUMBER PART NAME F75Z-18A318-AA Vacuum Motor Assembly OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971919A Replace Vacuum Motor 0.6 Hr. Assembly DEALER CODING CONDITION BASIC PART NO. CODE 18A318 X2 OASIS CODES: 208000, 208300, 208999 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Air Door Actuator / Motor: > 97-13-18 > Jun > 97 > Radio Whining Noise on AM Band With A/C ON Air Door Actuator / Motor: Customer Interest Radio - Whining Noise on AM Band With A/C ON Article No. 97-13-18 06/23/97 ^ RADIO - "WHINING" IN AM RADIO BAND WHILE DRIVING - VEHICLES BUILT THROUGH 5/30/97 ^ NOISE - "WHINING" IN AM RADIO BAND - VEHICLES BUILT THROUGH 5/30/97 LIGHT TRUCK: 1997 EXPEDITION, F-150, F-250 LD ISSUE: There may be a "whining" noise heard through the radio while in AM band below 1100 kHz with the A/C temperature control at Full Cool or Full Heat. On vehicles with rear A/C units, the rear temperature or mode controls may be at any position. In some situations the noise may change when vehicle loads are switched on and off. This may be caused by electromagnetic interference from the blend door actuator. ACTION: Verify condition and replace the front and rear (if equipped) blend door actuators. Changing the position of the temperature or rear mode control will eliminate the noise and verify the condition exists. The new actuators have been revised to reduce potential electromagnetic interference which should reduce the possibility of whine heard through the radio. Refer to the 1997 F-Series or Expedition Workshop Manual for removal and installation procedures. NOTE: FOR EXPEDITION ONLY: THE EVAPORATOR ASSEMBLY MUST BE REMOVED TO GAIN ACCESS TO THE BLEND DOOR ACTUATOR. FOLLOW PROCEDURE OUTLINED IN THE 1997 EXPEDITION SERVICE MANUAL, SECTION 412-03. PART NUMBER PART NAME F85Z-19E616-AA Blend Door Actuator - Front F85Z-19E616-BA Blend Door Actuator - Rear (Expedition) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971318A Replace Front Blend Door 4.3 Hrs. Actuator - Expedition 971318B Replace Front And Rear 4.7 Hrs. Blend Door Actuators - Expedition 971318C Replace Blend Door 0.8 Hr. Actuator - F-150 971318D Additional Time For 0.3 Hr. Vehicles Equipped With Center Console 971318E Additional Time For 0.2 Hr. Vehicles Equipped With Center Console - F-150 DEALER CODING CONDITION BASIC PART NO. CODE 19E616 D4 OASIS CODES: 207000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Door Actuator / Motor: > 97-19-19 > Sep > 97 > A/C - No Airflow From Floor Vents Air Door Actuator / Motor: All Technical Service Bulletins A/C - No Airflow From Floor Vents Article No. 97-19-19 09/15/97 ^ AIR CONDITIONING - NO AIRFLOW FROM FLOOR HEATER - NO AIRFLOW FROM FLOOR LIGHT TRUCK: 1997 EXPEDITION, F-150-350 SERIES ISSUE: Airflow from the air conditioner or heater will not switch to FLOOR mode on some vehicles. This may be due to the panel/floor door vacuum motor linkage being disconnected from the door pivot. ACTION: Replace the vacuum motor assembly. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify concern. 2. Remove and replace panel/floor door Vacuum Motor (F75Z-18A318-AA). Refer to the appropriate Service Manual for removal procedure. Make sure linkage is fully engaged in door pivot. 3. Verify proper heating system operation. PART NUMBER PART NAME F75Z-18A318-AA Vacuum Motor Assembly OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971919A Replace Vacuum Motor 0.6 Hr. Assembly DEALER CODING CONDITION BASIC PART NO. CODE 18A318 X2 OASIS CODES: 208000, 208300, 208999 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Door Actuator / Motor: > 97-13-18 > Jun > 97 > Radio - Whining Noise on AM Band With A/C ON Air Door Actuator / Motor: All Technical Service Bulletins Radio - Whining Noise on AM Band With A/C ON Article No. 97-13-18 06/23/97 ^ RADIO - "WHINING" IN AM RADIO BAND WHILE DRIVING - VEHICLES BUILT THROUGH 5/30/97 ^ NOISE - "WHINING" IN AM RADIO BAND - VEHICLES BUILT THROUGH 5/30/97 LIGHT TRUCK: 1997 EXPEDITION, F-150, F-250 LD ISSUE: There may be a "whining" noise heard through the radio while in AM band below 1100 kHz with the A/C temperature control at Full Cool or Full Heat. On vehicles with rear A/C units, the rear temperature or mode controls may be at any position. In some situations the noise may change when vehicle loads are switched on and off. This may be caused by electromagnetic interference from the blend door actuator. ACTION: Verify condition and replace the front and rear (if equipped) blend door actuators. Changing the position of the temperature or rear mode control will eliminate the noise and verify the condition exists. The new actuators have been revised to reduce potential electromagnetic interference which should reduce the possibility of whine heard through the radio. Refer to the 1997 F-Series or Expedition Workshop Manual for removal and installation procedures. NOTE: FOR EXPEDITION ONLY: THE EVAPORATOR ASSEMBLY MUST BE REMOVED TO GAIN ACCESS TO THE BLEND DOOR ACTUATOR. FOLLOW PROCEDURE OUTLINED IN THE 1997 EXPEDITION SERVICE MANUAL, SECTION 412-03. PART NUMBER PART NAME F85Z-19E616-AA Blend Door Actuator - Front F85Z-19E616-BA Blend Door Actuator - Rear (Expedition) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971318A Replace Front Blend Door 4.3 Hrs. Actuator - Expedition 971318B Replace Front And Rear 4.7 Hrs. Blend Door Actuators - Expedition 971318C Replace Blend Door 0.8 Hr. Actuator - F-150 971318D Additional Time For 0.3 Hr. Vehicles Equipped With Center Console 971318E Additional Time For 0.2 Hr. Vehicles Equipped With Center Console - F-150 DEALER CODING CONDITION BASIC PART NO. CODE 19E616 D4 OASIS CODES: 207000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Page 9901 Air Door Actuator / Motor: Specifications Door Actuator Motor Bolts ................................................................................................................... ............................................ 2-3 N.m (18-26 Lb/In) Air Inlet Door Vacuum Motor Screws .............................................................................................................................................. 2-3 N.m (18-27 Lb/In) Electronic Actuator Screws .................................................................................................................. ............................................. 2-3 N.m (18-27 Lb/In) Panel/Defrost Door Vacuum Motor Screws ...................................................................................................................................... 2-3 N.m (18-27 Lb/In) Panel/Floor Door Vacuum Motor Screws ......................................................................................................................................... 2-3 N.m (18-27 Lb/In) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Auxiliary Blend Door Actuator Auxiliary Blend Door Actuator Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Auxiliary Blend Door Actuator > Page 9904 Blend Door Actuator Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Auxiliary Blend Door Actuator > Page 9905 Console Blend Door Actuator Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > A/C Electronic Actuator Air Door Actuator / Motor: Service and Repair A/C Electronic Actuator REMOVAL 1. If equipped, remove the floor duct panel. ^ Remove the two plastic push pins (one each side) and release the expander clip. 2. Remove the RH instrument panel brace. 1. Remove the lower nut. 2. Remove the upper bolt. 3. Remove the brace. 3. Remove the LH instrument panel lower nut and position brace aside. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > A/C Electronic Actuator > Page 9908 4. Remove the floor duct. 1. Remove the two screws (one each side). 2. Remove the floor duct. 5. Remove the electronic actuator. 1. Disconnect the electronic actuator electrical connector. 2. Remove the three actuator screws. 3. Pull down to release the actuator shaft and remove the electronic actuator. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > A/C Electronic Actuator > Page 9909 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > A/C Electronic Actuator > Page 9910 Air Door Actuator / Motor: Service and Repair Vacuum Control Motors Air Inlet Door REMOVAL 1. Remove the plenum assembly 2. Remove the air inlet door vacuum control motor. 1. Disconnect the vacuum line. 2. Remove the air inlet door vacuum control motor screws. 3. Remove the air inlet door vacuum control motor. ^ Rotate vacuum control motor to disconnect the vacuum control motor rod from air inlet door lever. INSTALLATION 1. To install, reverse the removal procedure. Panel/Defrost Door REMOVAL 1. Carefully pry to release the four clips and remove the steering column opening cover. NOTE: On vehicles equipped with automatic transmissions, move the shift control selector lever to the 1 position to make removal easier. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > A/C Electronic Actuator > Page 9911 2. Pull to release the three clips and remove the lower instrument panel steering column cover. 3. Position the hood latch release handle aside. 1. Remove the hood latch release handle screws. 2. Position the hood latch release handle aside. 4. Position the parking brake release handle aside. 1. Remove the parking brake release handle screws. 2. Position the parking brake release handle aside. 5. If equipped, remove the instrument panel floor duct panel. ^ Remove two push clips and release one expander clip. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > A/C Electronic Actuator > Page 9912 6. Remove the upper instrument panel steering column cover. 1. Remove the upper instrument panel steering column cover bolts. 2. Remove the upper instrument panel steering column cover. 7. Remove the panel/defrost door vacuum control motor. 1. Disconnect the vacuum line. 2. Remove the pushnut. 3. Remove the panel/defrost door vacuum control motor screws. 4. Remove the panel/defrost door vacuum control motor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > A/C Electronic Actuator > Page 9913 1. To install, reverse the removal procedure. Panel/Floor Door REMOVAL 1. If equipped, remove the floor duct panel. ^ Remove the two plastic push pins (one each side) and release the expander clip. 2. Remove the RH instrument panel brace. 1. Remove the lower nut. 2. Remove the upper bolt. 3. Remove the brace. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > A/C Electronic Actuator > Page 9914 3. Remove the LH instrument panel lower nut and position brace aside. 4. Remove the floor duct. 1. Remove the two screws (one each side). 2. Remove the floor duct. 5. Remove the panel/floor door vacuum control motor. 1. Disconnect the vacuum line connector. 2. Remove the panel/floor door vacuum control motor screws. 3. Slide the rod out of the door and remove the panel/floor door vacuum control motor. NOTE: Rotate the vacuum control motor to disconnect the vacuum control motor rod from the panel/floor door. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > A/C Electronic Actuator > Page 9915 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Position Sensor / Switch, HVAC > Component Information > Diagrams > Air Door Position Sensor / Switch, HVAC Air Door Position Sensor / Switch: Diagrams Air Door Position Sensor / Switch, HVAC Front Mode Potentiometer Rear Mode Potentiometer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Position Sensor / Switch, HVAC > Component Information > Diagrams > Air Door Position Sensor / Switch, HVAC > Page 9920 Air Door Position Sensor / Switch: Diagrams Blend Door Position Sensor Front Blend Potentiometer Rear Blend Potentiometer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Specifications Air Duct: Specifications Demister Nozzle and Duct Screws .................................................................................................................................................... 2-3 N.m (18-27 Lb/In) Floor Duct Screws .................................................................................................. ........................................................................... 2-3 N.m (18-27 Lb/In) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Specifications > Page 9924 Air Duct: Description and Operation AIR DUCTS AND REGISTERS Air ducts route air to specified areas of the air distribution system. These areas are the floor ducts, panel registers, side window demisters, and defrost nozzles. The panel registers are adjustable and are used to aim the discharged air to the desired area. The floor ducts, side window demisters, and defrost nozzles are non-adjustable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defrost Nozzles and Side Demister Ducts Air Duct: Service and Repair Defrost Nozzles and Side Demister Ducts REMOVAL 1. Remove the plenum assembly. 2. Remove the A/C plenum demister adapter. 1. Remove the screw. 2. Remove the A/C plenum demister adapter. 3. Remove the demister nozzle and duct. 1. Remove the screws. 2. Remove the demister nozzle and duct. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defrost Nozzles and Side Demister Ducts > Page 9927 Air Duct: Service and Repair Floor Duct REMOVAL 1. Remove the floor duct panel. ^ Remove the two plastic push pins (one each side) and release the expander clip. 2. Remove the RH instrument panel brace. 1. Remove the nut. 2. Remove the bolt. 3. Remove the brace. 3. Remove the LH instrument panel lower nut and position brace aside. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defrost Nozzles and Side Demister Ducts > Page 9928 4. Remove the floor duct. 1. Remove the two screws (one each side). 2. Remove the floor duct. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Specifications Air Register: Specifications Center Instrument Panel Register Screws .......................................................................................................................................... 2-3 N.m (18-27 Lb/In) RH Panel Register Screws .................................................................................................................. ............................................... 2-3 N.m (18-27 Lb/In) LH Panel Register Screws ................................................................................................................... .............................................. 2-3 N.m (18-27 Lb/In) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Specifications > Page 9932 Air Register: Description and Operation AIR DUCTS AND REGISTERS Air ducts route air to specified areas of the air distribution system. These areas are the floor ducts, panel registers, side window demisters, and defrost nozzles. The panel registers are adjustable and are used to aim the discharged air to the desired area. The floor ducts, side window demisters, and defrost nozzles are non-adjustable. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Center Air Register: Service and Repair Center REMOVAL 1. Remove the center instrument panel finish panel. 2. If equipped, disconnect the transfer case rotary control switch electrical connector. 3. Remove the center panel register(s). 1. Remove the screws. 2. Pry back the lock tabs. 3. Remove the panel register. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Center > Page 9935 Air Register: Service and Repair Left REMOVAL 1. Remove the steering column cover panel. 2. Remove the headlamp switch. 3. Remove the LH instrument panel finish panel. 1. Remove the screws. 2. Remove the instrument panel finish panel. 4. Remove the LH panel register. 1. Remove the screws. 2. Pry back the lock tabs. 3. Remove the LH panel register. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Center > Page 9936 1. To install, reverse removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Center > Page 9937 Air Register: Service and Repair Right REMOVAL 1. Remove the instrument panel. 2. Remove the RH panel register. 1. Remove the screws. 2. Remove the RH panel register. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Aspirator, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Aspirator: > 00-1-8 > Jan > 00 > A/C - Blower Motor Stays on HIGH Aspirator: Customer Interest A/C - Blower Motor Stays on HIGH Article No. 00-1-8 1/10/00 ^ AIR CONDITIONING - BLOWER MOTOR STAYS ON HIGH SPEED AFTER DESIRED TEMPERATURE HAS BEEN REACHED - EATC EQUIPPED VEHICLES ONLY ^ AIR CONDITIONING - SYSTEM DOES NOT MAINTAIN SET TEMPERATURE - EATC EQUIPPED VEHICLES ONLY FORD: 1997-2000 EXPEDITION LINCOLN: 1998-2000 NAVIGATOR ISSUE On some vehicles equipped with Electronic Automatic Temperature Control (EATC), the blower motor may stay on high after desired temperature is reached and/or the system does not maintain set temperature. ACTION Check for proper connection of the in-car temperature aspirator tube. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Cut a piece of toilet paper or tissue paper about 3.7x3.7 cm (1.5x1.5") (paper towel will not work). 2. Turn the key on and turn fan speed to HIGH. 3. Select PANEL or VENT mode. 4. Place the piece of tissue paper over the aspirator grille opening in the bezel. If aspiration (suction) is present, the tissue paper should stick to the aspirator grille. 5. Turn the fan OFF. The tissue paper should fall off. 6. If the tissue paper falls off the aspirator grille while the fan is on HIGH, check that the aspirator tube is properly connected at the right bottom corner of the front heater. The black connector on the white flexible tube should be snapped over the black tube connected to the heater plenum. Also, check for kinks and cuts in the aspirator tube. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204100, 205000, 208000, 208200, 208300, 208999 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Aspirator, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Aspirator: > 00-1-8 > Jan > 00 > A/C - Blower Motor Stays on HIGH Aspirator: All Technical Service Bulletins A/C - Blower Motor Stays on HIGH Article No. 00-1-8 1/10/00 ^ AIR CONDITIONING - BLOWER MOTOR STAYS ON HIGH SPEED AFTER DESIRED TEMPERATURE HAS BEEN REACHED - EATC EQUIPPED VEHICLES ONLY ^ AIR CONDITIONING - SYSTEM DOES NOT MAINTAIN SET TEMPERATURE - EATC EQUIPPED VEHICLES ONLY FORD: 1997-2000 EXPEDITION LINCOLN: 1998-2000 NAVIGATOR ISSUE On some vehicles equipped with Electronic Automatic Temperature Control (EATC), the blower motor may stay on high after desired temperature is reached and/or the system does not maintain set temperature. ACTION Check for proper connection of the in-car temperature aspirator tube. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Cut a piece of toilet paper or tissue paper about 3.7x3.7 cm (1.5x1.5") (paper towel will not work). 2. Turn the key on and turn fan speed to HIGH. 3. Select PANEL or VENT mode. 4. Place the piece of tissue paper over the aspirator grille opening in the bezel. If aspiration (suction) is present, the tissue paper should stick to the aspirator grille. 5. Turn the fan OFF. The tissue paper should fall off. 6. If the tissue paper falls off the aspirator grille while the fan is on HIGH, check that the aspirator tube is properly connected at the right bottom corner of the front heater. The black connector on the white flexible tube should be snapped over the black tube connected to the heater plenum. Also, check for kinks and cuts in the aspirator tube. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204100, 205000, 208000, 208200, 208300, 208999 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor: > 97-25-5 > Dec > 97 > Blower Motor - Chirping/Squeaking Blower Motor: Customer Interest Blower Motor - Chirping/Squeaking Article No. 97-25-5 12/08/97 ^ BLOWER MOTOR - "CHIRPING" OR "SQUEAKING" FROM BLOWER MOTOR AT LOW SPEEDS ^ NOISE - "CHIRPING" OR "SQUEAKING" FROM BLOWER MOTOR AT LOW SPEEDS FORD: 1984-94 TEMPO 1986-97 TAURUS 1989-97 THUNDERBIRD 1991-97 ESCORT 1994-97 MUSTANG 1995-97 CONTOUR LINCOLN-MERCURY: 1984-94 TOPAZ 1986-97 CONTINENTAL, SABLE 1989-97 COUGAR 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR 1993-97 VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, F-150, F-250 LD This TSB article is being republished in its entirety to correct the supersede article reference. ISSUE: Some vehicles may exhibit a "squeaking" or "chirping" from the blower motor at low blower motor speeds. This may be caused by uneven brush friction on the commutator surface of the motor. ACTION: Replace the blower motor with a revised blower motor which has improved brush-to-commutator friction. Refer to the appropriate model/year Service Manual for removal and installation procedures. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor: > 97-25-5 > Dec > 97 > Blower Motor - Chirping/Squeaking > Page 9959 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-23-4, 97-6-10 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-97 Model Year Vehicles And 1991 Continental, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 972505A Replace Blower Motor - All Refer to Vehicles SLTS Manual DEALER CODING CONDITION BASIC PART NO. CODE 19805 14 OASIS CODES: 208000, 208300, 208999, 702000, 702300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor: > 97-12-10 > Jun > 97 > Blower Motor - Vibration/Noise from Center Console Blower Motor: Customer Interest Blower Motor - Vibration/Noise from Center Console Article No. 97-12-10 06/09/97 ^ BLOWER MOTOR - VIBRATION OR "FLUTTERING" NOISE COMING FROM CENTER CONSOLE ^ NOISE - VIBRATION OR "FLUTTERING" NOISE FROM CENTER CONSOLE WITH BLOWER MOTOR OPERATING LIGHT TRUCK: 1997 EXPEDITION ISSUE: A vibration or "fluttering" noise coming from the center console when the blower motor is operating may be heard on some vehicles. This may be due to a blower motor assembly imbalance. ACTION: Replace the blower motor/wheelhousing assembly. The new blower assembly is balanced at the factory. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify concern. 2. Remove the floor console. Refer to the 1997 Expedition Workshop Manual, Section 501-12 for details. 3. Remove the eight (8) screws from the floor console support braces. Remove the braces. Refer to Figure 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor: > 97-12-10 > Jun > 97 > Blower Motor - Vibration/Noise from Center Console > Page 9964 4. Remove the two (2) screws from the blower motor duct. Remove the duct. Refer to Figure 2. 5. Remove the three (3) blower motor assembly nuts. Remove the blower assembly. Refer to Figure 3. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor: > 97-12-10 > Jun > 97 > Blower Motor - Vibration/Noise from Center Console > Page 9965 6. Disconnect the electrical connectors. Refer to Figure 4. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor: > 97-12-10 > Jun > 97 > Blower Motor - Vibration/Noise from Center Console > Page 9966 7. Replace the assembly with a revised Center Console Blower Motor Assembly (F77Z-18456-BA) by reversing Steps 2-6. Refer to Figures 5-7. 8. Verify repair. PART NUMBER PART NAME F77Z-18456-BA Center Console Blower Assembly OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971210A Replace Blower Motor 0.8 Hr. Wheelhousing Assembly DEALER CODING CONDITION BASIC PART NO. CODE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor: > 97-12-10 > Jun > 97 > Blower Motor - Vibration/Noise from Center Console > Page 9967 18456 12 OASIS CODES: 208000, 208999, 702000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor: > 97-25-5 > Dec > 97 > Blower Motor - Chirping/Squeaking Blower Motor: All Technical Service Bulletins Blower Motor - Chirping/Squeaking Article No. 97-25-5 12/08/97 ^ BLOWER MOTOR - "CHIRPING" OR "SQUEAKING" FROM BLOWER MOTOR AT LOW SPEEDS ^ NOISE - "CHIRPING" OR "SQUEAKING" FROM BLOWER MOTOR AT LOW SPEEDS FORD: 1984-94 TEMPO 1986-97 TAURUS 1989-97 THUNDERBIRD 1991-97 ESCORT 1994-97 MUSTANG 1995-97 CONTOUR LINCOLN-MERCURY: 1984-94 TOPAZ 1986-97 CONTINENTAL, SABLE 1989-97 COUGAR 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR 1993-97 VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, F-150, F-250 LD This TSB article is being republished in its entirety to correct the supersede article reference. ISSUE: Some vehicles may exhibit a "squeaking" or "chirping" from the blower motor at low blower motor speeds. This may be caused by uneven brush friction on the commutator surface of the motor. ACTION: Replace the blower motor with a revised blower motor which has improved brush-to-commutator friction. Refer to the appropriate model/year Service Manual for removal and installation procedures. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor: > 97-25-5 > Dec > 97 > Blower Motor - Chirping/Squeaking > Page 9973 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-23-4, 97-6-10 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-97 Model Year Vehicles And 1991 Continental, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 972505A Replace Blower Motor - All Refer to Vehicles SLTS Manual DEALER CODING CONDITION BASIC PART NO. CODE 19805 14 OASIS CODES: 208000, 208300, 208999, 702000, 702300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor: > 97-12-10 > Jun > 97 > Blower Motor - Vibration/Noise from Center Console Blower Motor: All Technical Service Bulletins Blower Motor - Vibration/Noise from Center Console Article No. 97-12-10 06/09/97 ^ BLOWER MOTOR - VIBRATION OR "FLUTTERING" NOISE COMING FROM CENTER CONSOLE ^ NOISE - VIBRATION OR "FLUTTERING" NOISE FROM CENTER CONSOLE WITH BLOWER MOTOR OPERATING LIGHT TRUCK: 1997 EXPEDITION ISSUE: A vibration or "fluttering" noise coming from the center console when the blower motor is operating may be heard on some vehicles. This may be due to a blower motor assembly imbalance. ACTION: Replace the blower motor/wheelhousing assembly. The new blower assembly is balanced at the factory. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify concern. 2. Remove the floor console. Refer to the 1997 Expedition Workshop Manual, Section 501-12 for details. 3. Remove the eight (8) screws from the floor console support braces. Remove the braces. Refer to Figure 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor: > 97-12-10 > Jun > 97 > Blower Motor - Vibration/Noise from Center Console > Page 9978 4. Remove the two (2) screws from the blower motor duct. Remove the duct. Refer to Figure 2. 5. Remove the three (3) blower motor assembly nuts. Remove the blower assembly. Refer to Figure 3. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor: > 97-12-10 > Jun > 97 > Blower Motor - Vibration/Noise from Center Console > Page 9979 6. Disconnect the electrical connectors. Refer to Figure 4. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor: > 97-12-10 > Jun > 97 > Blower Motor - Vibration/Noise from Center Console > Page 9980 7. Replace the assembly with a revised Center Console Blower Motor Assembly (F77Z-18456-BA) by reversing Steps 2-6. Refer to Figures 5-7. 8. Verify repair. PART NUMBER PART NAME F77Z-18456-BA Center Console Blower Assembly OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971210A Replace Blower Motor 0.8 Hr. Wheelhousing Assembly DEALER CODING CONDITION BASIC PART NO. CODE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor: > 97-12-10 > Jun > 97 > Blower Motor - Vibration/Noise from Center Console > Page 9981 18456 12 OASIS CODES: 208000, 208999, 702000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Page 9982 Blower Motor: Specifications Blower Motor Screws ........................................................................................................................... ......................................... 2-3.5 N.m (18-31 Lb/In) Blower Motor Cover Screws ................................................................................................................ ................................................. 1-2 N.m (9-7 Lb/In) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Auxiliary A/C Blower Motor Auxiliary A/C Blower Motor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Auxiliary A/C Blower Motor > Page 9985 Blower Motor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Auxiliary A/C Blower Motor > Page 9986 Console Blower Motor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Auxiliary Blower Motor System Blower Motor: Description and Operation Auxiliary Blower Motor System Blower motor operation is controlled from either the rear or the front auxiliary climate control bead. The climate control heads are located in overhead consoles over the front and second row seat assemblies. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Auxiliary Blower Motor System > Page 9989 Blower Motor: Description and Operation With Manual A/C - Heater Blower Motor The A/C blower motor pulls air from the air inlet and forces it into the plenum assembly where it is mixed and distributed. The A/C blower motor has four speeds and is controlled by the blower motor switch and resistor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Auxiliary Blower Motor Blower Motor: Service and Repair Auxiliary Blower Motor REMOVAL 1. Remove the quarter trim panel access cover. 2. Remove the blower motor. 1. Disconnect the electrical connector. 2. Remove the three motor cover bolts. 3. Remove the blower motor cover. 4. Remove the blower motor bolts. 5. Remove the blower motor. 3. Remove the wheel from the blower motor. 1. Remove the push clip. 2. Remove the wheel. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Auxiliary Blower Motor > Page 9992 Blower Motor: Service and Repair Heating and Defrosting REMOVAL 1. If equipped, remove the aftermarket air filter. 2. If equipped, remove the mounting bracket for the removed cover. 3. Disconnect the christmas tree retainer from the motor mounting plate. 4. Disconnect the motor electrical connector. 5. Remove the blower motor cover. 1. Remove the three screws. 2. Pry to release the three tabs. 3. Remove the cover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Auxiliary Blower Motor > Page 9993 6. Remove the blower motor. 1. Remove the three screws. 2. Remove the blower motor. CAUTION: Carefully remove the blower motor so as not to damage the wheel 7. Remove the wheel from the blower motor. 1. Remove the push clip. 2. Remove the wheel. 8. Remove the gasket. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 9997 Power/Flasher Relay Block The Blower Relay is located in the blower/flasher relay block. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 9998 Blower Motor Relay: Testing and Inspection Digital Multimeter Special Tools RELAY COMPONENT TEST Testing of an ISO relay can be accomplished through the use of three No. 10 (or larger gauge) jumper wires and a 73 Digital Multimeter. Remove (unplug) the relay to be tested from the engine compartment fuse junction panel, I/P fuse junction panel or individual connector. Mini ISO Relay Use 73 Digital Multimeter to check for the continuity between terminal 85 and all other terminals. If resistance is 5 ohms or less between terminal 85 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay terminals 86 and 30 directly to the positive battery terminal. With the multimeter set in the volts position, check for voltage at terminal 87A. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 85 and ground the jumper wire to a known good ground. Check for voltage at terminal 87. If battery voltage is not indicated, replace the relay. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 9999 Blower Motor Relay: Tools and Equipment Digital Multimeter Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Specifications Blower Motor Resistor: Specifications Blower Motor Resistor Screws .......................................................................................................................................................... 2-3 N.m (18-27 Lb/In) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Auxiliary Blower Resistors Auxiliary A/C Blower Motor Resistor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Auxiliary Blower Resistors > Page 10005 Blower Motor Resistor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Auxiliary Blower Resistors > Page 10006 Console Blower Motor Resistor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Auxiliary A/C-Heating Blower Motor Resistor: Service and Repair Auxiliary A/C-Heating REMOVAL 1. Remove the quarter trim panel access cover. 2. Disconnect the electrical connector. 3. Remove the A/C blower motor resistor. 1. Remove the bolts. 2. Remove the A/C blower motor resistor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Auxiliary A/C-Heating > Page 10009 Blower Motor Resistor: Service and Repair Blower Motor Resistor REMOVAL 1. Remove the blower motor resistor. 1. Disconnect the blower motor resistor electrical connector. 2. Remove the blower motor resistor screws. 3. Remove the blower motor resistor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Blower Switch Blower Motor Switch: Diagrams Blower Switch Front Blower Motor Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Blower Switch > Page 10014 Rear Blower Motor Switch Rear Integrated Control Panel (Rear Blower Switch) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Blower Switch > Page 10015 Blower Motor Switch: Diagrams Blower Switch Illumination Front Blower Switch Illumination Rear Blower Switch Illumination Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Testing and Inspection > Blower Switch Blower Motor Switch: Testing and Inspection Blower Switch Blower Motor Switch - Component Testing Procedure Blower Motor Switch - Terminal Locations Blower Motor Switch - Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Testing and Inspection > Blower Switch > Page 10018 Blower Motor Switch: Testing and Inspection Front Blower Switch Front Blower Motor Switch - Component Testing Procedure Front Blower Motor Switch - Terminal Locations Front Blower Motor Switch - Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Testing and Inspection > Blower Switch > Page 10019 Blower Motor Switch: Testing and Inspection Rear Auxiliary Rear Blower Motor Switch - Component Testing Procedure Rear Blower Motor Switch - Terminal Locations Rear Blower Motor Switch - Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair Note: Not all of these vehicles were equipped with a Cabin Air Filter. Only vehicles with a filter cover in the location shown have a Cabin Air Filter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications Compressor Clutch: Specifications Air Gap Between Clutch Pulley and Clutch ..................................................................................................................... 0.45-0.85 mm (0.018-0.033 Inch) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 10027 Compressor Clutch: Description and Operation A magnetic clutch is used to drive the compressor shaft. When voltage is applied to the clutch field coil, the clutch plate and hub assembly (which is solidly coupled to the compressor shaft) is drawn rearward by magnetic force toward the A/C clutch pulley which rotates freely on the compressor front head casting. The magnetic force locks the clutch plate and hub assembly and the pulley together as one unit. The compressor shaft then turns with the pulley. When voltage is removed from the clutch field coil, springs in the clutch plate and hub assembly move the clutch plate away from the pulley. The clutch plate and hub assembly and the compressor shaft cease to rotate. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 10028 Compressor Clutch: Adjustments 1. Check the A/C clutch air gap at three equally spaced places between the clutch hub and the A/C clutch pulley. 2. Add or remove shims between the A/C clutch and the compressor shaft until clearance is within specification. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 10029 Compressor Clutch: Service and Repair Jaw Puller Differential Side Bearing Puller Coil Pressing Tool Field Coil Replacer Compressor Clutch Holding Tool Shaft Protector Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 10030 Special Tools REMOVAL 1. Use (A) Compressor Clutch Holding Tool to remove the (B) A/C clutch bolt. NOTE: Before disassembling the A/C compressor, check the A/C clutch air gap. 2. Pull the A/C clutch and shims from the compressor shaft. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 10031 3. Remove the pulley snap ring. 4. Remove the A/C clutch pulley and the A/C compressor pulley bearing. 5. Remove the A/C clutch field coil. 1. Position Shaft Protector on the nose opening of the compressor. 2. Use (A) Differential Side Bearing Puller to remove the (B) field coil. CAUTION: Do not use air tools. INSTALLATION 1. Clean the A/C clutch field coil mounting surface head. 2. Use (A) Field Coil Replacer, (B) Coil Pressing Tool and (C) 2-Jaw Puller to install the (D) A/C clutch field coil. NOTE: Check that the A/C clutch field coil outer diameter bottoms completely against the head. Ensure that the coil electrical connector is correctly positioned. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 10032 3. Install the A/C compressor pulley hearing and the A/C pulley. 4. Install the pulley snap ring with the bevel side out. 5. Place one nominal thickness shim inside the hub spline opening. 6. Slide the hub onto the compressor shaft. 7. Use (A) Compressor Clutch Holding Tool to install a new (B) A/C clutch bolt. ^ Inspect the air gap. 8. Install the A/C compressor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 10033 Compressor Clutch: Tools and Equipment Jaw Puller Differential Side Bearing Puller Coil Pressing Tool Field Coil Replacer Compressor Clutch Holding Tool Shaft Protector Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 10034 Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Specifications > Air Gap Compressor Clutch Hub: Specifications Air Gap Item ...................................................................................................................................................... ............................................................ Specification Air Gap Between Pulley and Hub .................................................................................................................................... 0.45-0.85 mm (0.018-0.033 inch) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Specifications > Air Gap > Page 10039 Compressor Clutch Hub: Specifications Torque A/C Compressor Clutch Hub Bolt ................................................................................................................................................. 11-13 N.m (14-18 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair Compressor Shaft Seal: Service and Repair Shaft Seal Protector O-Ring Tool Shaft Seal Remover Shaft Seal Replacer Snap Ring Remover Special Tools REMOVAL 1. Recover the refrigerant from the system. 2. Remove the A/C compressor. 3. Remove the A/C clutch from the A/C compressor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > Page 10043 4. Use (A) O-Ring Tool to remove the (B) shaft seal felt from the nose of the A/C compressor. 5. Clean the compressor nose area. 6. Use (A) Snap Ring Remover to remove the (B) shaft seal snap ring. 7. Engage (A) Shaft Seal Remover into the (B) internal diameter of the shaft seal. 8. Turn the tool handle clockwise to expand the tool tip inside of the shaft seal. 9. Pull the seal from the compressor. INSTALLATION CAUTION: Do not allow dirt or other foreign materials to enter the compressor. NOTE: Obtain a new A/C Compressor Shaft Seal Kit. Carefully remove the contents of the kit and inspect the plastic shaft seal protector for burrs or other damage. DO NOT USE IF IT IS DAMAGED. 1. Clean the compressor nose area. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > Page 10044 2. Position the (A) shaft seal on the (B) Shaft Seal Protector. 3. Lubricate Shaft Seal Protector and shaft seal. ^ Use Motorcraft YN-12b Refrigerant Oil F2AZ-19577-AC or equivalent meeting Ford specification WSH-M1C231-B. 4. Position the shaft seal and Shaft Seal Protector over compressor shaft. 5. Use Shaft Seal Replacer to install the seal. 6. Remove Shaft Seal Replacer and Shaft Seal Protector. 7. Install a new shaft seal snap ring. 8. Conduct a leak test. 9. Install a new shaft seal felt in the compressor nose. 10. Install the A/C clutch on the A/C compressor. 11. Check and adjust the air gap as necessary. 12. Leak test the A/C system. 13. Evacuate and charge the system. See: Service and Repair/Evacuation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > Page 10045 Compressor Shaft Seal: Tools and Equipment Shaft Seal Protector O-Ring Tool Shaft Seal Remover Shaft Seal Replacer Snap Ring Remover Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations As shown in the wiring diagrams, these vehicles do not use a compressor cut-off (also called a wide open throttle or WOT) relay. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications Compressor Fitting HVAC: Specifications Manifold Tube Bolt ............................................................................................................................... ........................................ 18-24 N.m (14-18 Lb/Ft) Manifold Tube Fitting ............................................................................................................................................................. 25.5-34.5 N.m (19-25 Lb/Ft) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications > Page 10052 Compressor Fitting HVAC: Service and Repair REMOVAL CAUTION: Whenever a refrigerant line is replaced, it is necessary to replace the suction accumulator/drier. 1. Disconnect the battery ground cable. 2. Recover the refrigerant from the system. 3. Remove the A/C air inlet duct. 4. Remove the manifold and tube assembly. 1. Remove the manifold to compressor bolt. 2. Remove the manifold and tube assembly. 5. Disconnect the A/C pressure cut-off switch electrical connector. 6. Disconnect the manifold and tube fitting at the accumulator drier. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications > Page 10053 7. Disconnect the A/C condenser core inlet and outlet lines. 1. Remove the nuts. 2. Disconnect the A/C condenser core inlet and outlet lines. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications Condenser HVAC: Specifications A/C Condenser Bracket Bolts ................................................................................................................................................... 7.6-10.4 N.m (66-92 Lb/In) A/C Condenser Line Nuts ........................................................................................................................................................... 6.8-9.2 N.m (61-82 Lb/In) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 10057 Condenser HVAC: Description and Operation NOTE: Whenever an A/C condenser core is replaced, it is also necessary to replace the suction accumulator/drier. The A/C condenser core is an aluminum fin and tube design heat exchanger located in front of the vehicle radiator. It cools compressed refrigerant gas by allowing air to pass over fins and tubes to extract heat, and by condensing gas to liquid refrigerant as it is cooled. The A/C condenser core inlet and outlet connections are the male fitting of a tube O-ring fitting. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 10058 Condenser HVAC: Service and Repair REMOVAL CAUTION: Whenever an A/C condenser core is replaced, replace the suction accumulator/drier. If an A/C condenser core leak is suspected, the A/C condenser core must be leak-tested before it is removed from the vehicle. 1. Disconnect the battery ground cable. 2. Recover the refrigerant from the system. 3. Remove the radiator. 4. Disconnect the A/C condenser core inlet and outlet lines. 1. Remove the nuts. 2. Disconnect the A/C condenser core inlet and outlet hoses. 5. Remove the A/C condenser core. 1. Remove the bolts. 2. Remove the A/C condenser brackets. 3. Remove the A/C condenser core. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 10059 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Specifications Control Assembly: Specifications Climate Control Head Screws ........................................................................................................................................................... 2-3 N.m (18-27 Lb/In) Auxiliary Climate Control to Bezel Screws ...................................................................................................................................... 2-3 N.m (18-27 Lb/In) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Blend Door Potentiometer Function Selector Switch (Blend Door Potentiometer) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Blend Door Potentiometer > Page 10065 Function Selector Switch (Blower Motor Switch) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Blend Door Potentiometer > Page 10066 Function Selector Switch (Illumination) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Blend Door Potentiometer > Page 10067 Function Selector Switch (Mode Selector Switch) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Auxiliary Air Conditioning and Heating System Control Assembly: Description and Operation Auxiliary Air Conditioning and Heating System The auxiliary A/C system has dual controls for the driver and for passenger consisting of temperature, blower speed, and mode. The driver controls are mounted in the overhead console. The passenger controls are mounted in a separate console positioned on the roof trim panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Auxiliary Air Conditioning and Heating System > Page 10070 Control Assembly: Description and Operation Control Components Control System Inputs The climate control system inputs are selected manually from the climate control head. Manual Climate Control Head (In-Dash) Front Manual Climate Control Head (Overhead Console) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Auxiliary Air Conditioning and Heating System > Page 10071 Rear Manual Climate Control Head (Overhead Console) Control System Outputs Air Management Doors The air management doors are controlled by vacuum control motors and an A/C electronic door actuator motor. The air inlet and distribution doors are controlled by a vacuum control motor. The temperature blend door is controlled by the A/C electronic door actuator motor. The A/C electronic door actuator motor provides a variable number of temperature blend door positions. The temperature control position energizes the A/C electronic door actuator motor moving the temperature blend door. Vacuum control motors are used on both air distribution and air inlet doors. The air inlet and panel/defrost doors use a two position vacuum control motor. The floor duct/panel door uses a three position vacuum control motor. Vacuum control motors are controlled by engine vacuum through the climate control head. Blower Motor Circuit The blower motor circuit consists of a blower motor switch, a heater blower motor switch resistor with a thermal limiter, and the blower motor. Blower motor speed is determined by changing the current flow to the blower motor using resistors. The blower motor switch has four speeds that are obtained using three resistors that are wired in series. The heater blower motor switch resistor is wired into the blower motor ground circuit. ^ High Speed Current through the blower motor bypasses all resistors and travels directly to ground. ^ Medium High Speed - Current travels through one resistor and then to ground reducing current flow and blower motor speed. ^ Medium Low Speed - Current travels through two resistors reducing current flow and blower motor speed. ^ Low Speed - Current flow travels through all three resistors adding the highest resistance, causing the blower motor to run at its slowest speed. The thermal limiter is integral to the heater blower motor switch resistor and serves as a temperature protection device. The thermal limiter is wired in series with the heater blower motor switch resistor and opens when the resistor reaches approximately 121°C (250°F). When the thermal limiter opens, the blower motor will only operate on high speed. The thermal limiter does not reset; once opened, the heater blower motor switch resistor must be replaced. Manual Climate Control System The manual climate control system heats and/or cools the vehicle interior depending on the function selector position and the temperature selected. Function selector position determines heating or cooling and air distribution. The temperature blend control setting determines air temperature. The manual climate control components are used to: ^ Select air inlet source (fresh/recirculated). ^ Select blower motor speed. ^ Select discharge air temperature (temperature blend). ^ Select discharge air location (defrost, panel, floor). ^ Select compressor clutch operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Auxiliary Air Conditioning and Heating System > Page 10072 Control Assembly: Description and Operation Heating and Defrosting The control assembly is located in the instrument panel. The control assembly contains: ^ A four position heater blower motor switch. ^ A temperature control knob. ^ A function selector switch. ^ Illumination bulbs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Auxiliary Climate Control Head Control Assembly: Service and Repair Auxiliary Climate Control Head Front REMOVAL 1. Remove the front auxiliary climate control head. 1. Remove the screw. 2. Carefully release the three clips and slide the roof console forward. 3. Disconnect the electrical connectors. 2. Remove the auxiliary climate control head from the bezel. 1. Disconnect the electrical connectors. 2. Remove the screws. 3. Remove the control head. INSTALLATION 1. To install, reverse the removal procedure. Rear REMOVAL Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Auxiliary Climate Control Head > Page 10075 1. Remove the rear auxiliary climate control head assembly. 1. Slide the assembly forward and downward. 2. Disconnect the electrical connectors. 2. Remove the rear climate control head from the bezel. 1. Disconnect the electrical connectors. 2. Remove the screws. 3. Remove the control head. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Auxiliary Climate Control Head > Page 10076 Control Assembly: Service and Repair Bulbs REMOVAL 1. Disconnect the battery ground cable. 2. Remove the center instrument panel finish panel. ^ Carefully pry to release the four clips. 3. If equipped, disconnect the 4WD rotary control switch electrical connector. 4. Remove the climate control head. 1. Remove the climate control head screws. 2. Pull out the climate control head. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Auxiliary Climate Control Head > Page 10077 5. Disconnect the climate control head. 1. Disconnect the electrical connectors. 2. Disconnect the vacuum line connector. 6. Remove the two illumination bulbs. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Auxiliary Climate Control Head > Page 10078 Control Assembly: Service and Repair Climate Control Head REMOVAL WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE INJURY, THE AIR BAG BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE SERVICING OR REPLACING ANY AIR BAG SYSTEM COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY TO STARTER RELAY CABLE AND WAIT ONE MINUTE. 1. Disconnect the battery ground cable. 2. Remove the instrument panel relay cover. 3. Disconnect the two passenger air bag defeat switch electrical connectors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Auxiliary Climate Control Head > Page 10079 4. Remove the center instrument panel finish panel. ^ Carefully pry to release the four clips. 5. If equipped disconnect the 4WD rotary control switch electrical connector. 6. Remove the climate control head. 1. Remove the four climate control head screws. 2. Pull out the climate control head. 7. Disconnect the climate control head. 1. Disconnect the four electrical connectors. 2. Disconnect the vacuum line connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Auxiliary Climate Control Head > Page 10080 8. Remove the function selector. 1. Depress the two snap tabs. 2. Remove the function selector. NOTE: The knob will drop off as the function selector is removed. 9. Remove the temperature blend control switch. 1. Remove the temperature blend control screw. 2. Rotate and pull the temperature blend control. NOTE: The knob will drop off as the temperature blend control switch is removed. 10. Remove the blower motor switch. 1. Depress the three snap tabs. 2. Remove the blower motor switch. NOTE: The knob will drop off as the blower motor switch is removed. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Auxiliary Climate Control Head > Page 10081 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Technical Service Bulletins > A/C - R134a Tracer Dye and Three O Ring Spring Couplers A/C Coupler O-ring: Technical Service Bulletins A/C - R134a Tracer Dye and Three O Ring Spring Couplers Article No. 97-3-5 02/03/97 AIR CONDITIONING - R-134A TRACER DYE INSTALLED IN A/C SYSTEM AND THREE 0-RING SPRING LOCK COUPLERS - SERVICE TIP FORD: 1996-97 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1996-97 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VIII, MYSTIQUE, SABLE, TOWN CAR, TRACER LIGHT TRUCK: 1996 BRONCO 1996-97 AEROSTAR, ECONOLINE, EXPLORER, F-150-350 SERIES, RANGER, WINDSTAR 1997 EXPEDITION, MOUNTAINEER This TSB article is being republished in its entirety to update the text. ISSUE: Ford Motor Company now produces new vehicles with R-134a fluorescent tracer dye incorporated into the A/C system and spring lock couplings which contain three (3) O-rings. ACTION: Leak checking can be performed with the use of a Rotunda UV Lamp (112-R0021) and is an acceptable alternative to using an electronic leak detector. Ford Motor Company has begun implementation of spring lock couplings with three (3) O-rings which provide an improved seal. Field and laboratory tests have shown a 40% improvement in sealing capability and durable life. Through field and fleet testing and analysis, it is apparent that lubricating oil used in vehicle assembly processes is easily misdiagnosed as a refrigerant leak. The presence of oil at connections is not necessarily an indication of a leaking connection. If oil at a fitting is due to a leak, fluorescent tracer dye will be present at the location. Any oil escaping from the A/C hoses will contain dye. When checking for leaks, be sure to scan all components, fittings and lines of the A/C system with the UV lamp. The exact location of the leak or leaks can be pinpointed by the bright yellow-green glow of the tracer dye. Since more than one leak may exist in the system, always inspect each component. The best leak detection results will be achieved in conditions of low ambient light. In areas that cannot be reached by the UV lamp: (1) use a technician's mirror or (2) use a non-fluorescent shop towel, wipe the suspected area, and then check the towel with the UV lamp for traces of the dye. After the leak is repaired, the traces of dye can be removed from the previously leaking areas by using any general purpose oil solvent. Verify the repair by operating the A/C system for a short while and reinspecting the system with the UV lamp. NOTE: BEGINNING WITH VEHICLES PRODUCED IN MAY 1996, THE TRACER DYE'S FLUORESCENT LIFESPAN IS THE LIFE OF THE VEHICLE. VEHICLES PRODUCED BEFORE MAY 1996 CONTAIN A TRACER DYE WITH A LIFESPAN OF ROUGHLY 500 HOURS OF NC SYSTEM USE, AFTER WHICH TIME ANOTHER INFUSION OF DYE WOULD BE REQUIRED. REFER TO TSB 94-26-6 AND 95-21-4 IF ADDITIONAL TRACER DYE OR INFORMATION IS REQUIRED. OTHER APPLICABLE ARTICLES: 94-23-10, 94-26-6, 95-21-4, 96-15-6 SUPERSEDES: 95-21-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200, 208999 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest: > 97-16-11 > Aug > 97 > A/C - Condensate Dripping Onto Passenger Floor Evaporator Case: Customer Interest A/C - Condensate Dripping Onto Passenger Floor Article No. 97-16-11 08/04/97 AIR CONDITIONING - CONDENSATE DRIPS ONTO PASSENGER FLOOR DURING HUMID CONDITIONS LIGHT TRUCK: 1997 EXPEDITION, F-150-350 SERIES ISSUE: Condensate may drip onto the passenger floor during humid conditions with the A/C on. This may be caused by evaporator moisture running off and dripping onto the floor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest: > 97-16-11 > Aug > 97 > A/C - Condensate Dripping Onto Passenger Floor > Page 10095 ACTION: Install a Hush Panel kit. The hush panel acts as a tray to collect the condensate and allow it to evaporate without dripping onto the floor. Install the hush panel with three (3) screws as shown in Figure 1. PART NUMBER PART NAME F75Z-19803-BA Hush Panel Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971811A Install Hush Panel 0.3 Hr. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest: > 97-16-11 > Aug > 97 > A/C - Condensate Dripping Onto Passenger Floor > Page 10096 DEALER CODING CONDITION BASIC PART NO. CODE 19803 12 OASIS CODES: 110000, 208000, 208300, 208999 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 97-16-11 > Aug > 97 > A/C - Condensate Dripping Onto Passenger Floor Evaporator Case: All Technical Service Bulletins A/C - Condensate Dripping Onto Passenger Floor Article No. 97-16-11 08/04/97 AIR CONDITIONING - CONDENSATE DRIPS ONTO PASSENGER FLOOR DURING HUMID CONDITIONS LIGHT TRUCK: 1997 EXPEDITION, F-150-350 SERIES ISSUE: Condensate may drip onto the passenger floor during humid conditions with the A/C on. This may be caused by evaporator moisture running off and dripping onto the floor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 97-16-11 > Aug > 97 > A/C - Condensate Dripping Onto Passenger Floor > Page 10102 ACTION: Install a Hush Panel kit. The hush panel acts as a tray to collect the condensate and allow it to evaporate without dripping onto the floor. Install the hush panel with three (3) screws as shown in Figure 1. PART NUMBER PART NAME F75Z-19803-BA Hush Panel Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971811A Install Hush Panel 0.3 Hr. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 97-16-11 > Aug > 97 > A/C - Condensate Dripping Onto Passenger Floor > Page 10103 DEALER CODING CONDITION BASIC PART NO. CODE 19803 12 OASIS CODES: 110000, 208000, 208300, 208999 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Case: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions Speed Sensor: All Technical Service Bulletins Transfer Case - Multiple Electrical Malfunctions Article No. 01-16-6 08/20/01 ^ LAMP - 4X4 "LOW RANGE" LIGHT DIMLY LIT ^ SWITCHES - TRANSFER CASE MODE SWITCH - 4X4 HI/LOW SWITCH SHORTED OUT ^ WINDSHIELD WIPERS - INTERMITTENT WIPERS ERRATIC OR INOPERABLE ^ TRANSFER CASE - WATER PRESENT IN TRANSFER CASE FORD: 1997 EXPEDITION, F-150, F-250 LD This article is being republished in its entirety to update the labor time. ISSUE Water may be present in the transfer case on some vehicles. This may cause: ^ Transfer Case Mode Switch to become inoperative ^ The 4X4 "Low Range" light to appear dimly lit ^ The intermittent wipers to become erratic or inoperative ^ Vehicle Speed Sensor (VSS) Diagnostic Trouble Codes (DTCs) P0500, P0503, P1500, and P1501 to be set. This may be caused by water splashing into the transfer case through the vent tube assembly, possibly causing the transfer case mode switch to short out, and/or the VSS gear to swell and set the VSS DTCs listed above. Shorting out the transfer case mode switch may cause the intermittent wiper mode to function erratically, as well as possibly causing the 4X4 light to work incorrectly. ACTION Inspect, diagnose, and/or replace the necessary components. Refer to the following Service Procedure for details. SERVICE PROCEDURE Procedure for VSS Gear: 1. Inspect VSS gear in the transfer case for looseness. 2. Replace Gear (C80Z-17285-B) as necessary. Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Mode Switch: 1. Check resistance of the Transfer Case Mode Switch. 2. The resistance of the switch should be at least 100,000 ohms. If it is less, replace the switch (3-Position Switch, E7TZ-7E440-A, manual shift only). Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Vent Replacement: 1. Remove old vent hose from fitting on front of transfer case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Case: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 10109 2. Attach end of new Vent Hose (F75Z-7A246-M) to fitting, and route the hose up over the top of the transfer case (Figure 1). 3. Attach the clip on the vent hose to the top of the vertical rib on the transfer case extension housing to support the end of the hose (Figure 2). NOTE FOR ALL WATER CONCERNS, DRAIN AND REFILL THE TRANSFER CASE WITH FRESH FLUID (XT-2-QDX), AND REPLACE THE VENT HOSE WITH THE REVISED PART. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Case: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 10110 SUPERSEDES:97-11-19 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011606A Drain And Refill Transfer 1.2 Hrs. Case, Inspect And/Or Replace VSS Gear And Transfer Case Mode Switch, And Install Vent Kit DEALER CODING CONDITION BASIC PART NO. CODE 7D494 49 OASIS CODES: 202000, 206000, 508000, 508300, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Case: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 10116 2. Attach end of new Vent Hose (F75Z-7A246-M) to fitting, and route the hose up over the top of the transfer case (Figure 1). 3. Attach the clip on the vent hose to the top of the vertical rib on the transfer case extension housing to support the end of the hose (Figure 2). NOTE FOR ALL WATER CONCERNS, DRAIN AND REFILL THE TRANSFER CASE WITH FRESH FLUID (XT-2-QDX), AND REPLACE THE VENT HOSE WITH THE REVISED PART. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Case: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 10117 SUPERSEDES:97-11-19 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011606A Drain And Refill Transfer 1.2 Hrs. Case, Inspect And/Or Replace VSS Gear And Transfer Case Mode Switch, And Install Vent Kit DEALER CODING CONDITION BASIC PART NO. CODE 7D494 49 OASIS CODES: 202000, 206000, 508000, 508300, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications Evaporator Core: Specifications Evaporator to Expansion Valve Lines ................................................................................................................................. 12.7-17.3 N.m (113-154 Lb/In) Evaporator/Heater Core Access Cover Bolts .................................................................................................................................... 2-3 N.m (18-26 Lb/In) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Auxiliary Evaporator Core: Description and Operation Auxiliary The auxiliary A/C and heating system uses a rear-mounted evaporator core. The rear-mounted evaporator core operates the same as the front-mounted evaporator core. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Auxiliary > Page 10123 Evaporator Core: Description and Operation With Manual A/C A/C Evaporator Core NOTE: Whenever an A/C evaporator core is replaced, it is also necessary to replace the suction accumulator/drier. The A/C evaporator core is a multi-pass plate/fin aluminum core. The condenser to evaporator tube inlet connects to the bottom of the A/C evaporator core. The suction accumulator/drier outlet connects to the top of the A/C evaporator core. The A/C cycling switch senses pressure within the suction accumulator/drier and controls A/C compressor operation to regulate the pressure and temperature within the A/C evaporator core. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Page 10124 Evaporator Core: Testing and Inspection Digital Multimeter Set, A/C Fittings R-134a Automatic Calibration Halogen Leak Detector Radiator/Heater Core Pressure Tester Special Tools ON-VEHICLE LEAK TEST 1. Recover the A/C system. See: Service and Repair/Refrigerant Recovery 2. Disconnect the liquid line and suction accumulator/drier from the evaporator core tubes. Do not leak test an A/C evaporator core with the suction accumulator/drier attached to the A/C evaporator core. If the evaporator core tube fittings are the female spring lock design, check the inside of each fitting if possible for scratches and/or corrosion. If scratches or corrosion are found, the leak test results may not be accurate if a leak is indicated because of possible leaks at the fitting(s). 3. Connect the appropriate test fittings from the A/C Test Fitting Set to the evaporator tube connections. Then, connect the gauge set RED and BLUE hoses to the test fittings. Connect the YELLOW gauge set hose to a vacuum pump. NOTE: The automatic shut-off valves on some gauge set hoses do not open when connected to the test fittings. Use hoses without shut-off valves if available. If hoses with shut-off valves are used, check to be sure the valve opens when attached to the test fittings before installing the fittings and proceeding with the leak test. The test is not valid if the shut-off valve does not open because only the hose will be tested. 4. Open both gauge set valves and start the vacuum pump. Turn the heater blower motor on speed 1 and allow the vacuum pump to operate for a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Page 10125 minimum of 30 minutes after the gauge set low pressure gauge indicates 30 in-Hg. This 30 minutes evacuation is necessary to remove any refrigerant from oil left in the A/C evaporator core. If the refrigerant is not completely removed from the oil, gassing will occur and degrade the vacuum and appear as a refrigerant leak. After evacuating for 30 minutes, close the gauge set valves and stop the vacuum pump. Observe the low pressure gauge; it should remain at the 30 in-Hg mark. NOTE: A vacuum pump, like an automobile, requires maintenance for optimum performance. The condition of the vacuum pump oil is critical to pump performance and durability. Dirty and/or moisture-laden oil reduces the vacuum pump's ability to draw high vacuum levels that are required to extract refrigerant from the oil in the A/C evaporator core. As a general rule, vacuum pump manufacturers recommend replacing the oil in the vacuum pump after every 10 hours of operation. Some manufacturers may recommend even more frequent oil change intervals. 5. If the low pressure gauge reading will not drop to 30 in-Hg when the gauge set valves arc open and the vacuum pump is operating. close the gauge set valves and observe the low pressure gauge. If the pressure rises rapidly to zero, a large leak is indicated. Recheck the test fitting connections and gauge set connections before replacing the A/C evaporator. 6. If the low pressure gauge reading rises 10 or more inches of vacuum from the 30 in-Hg mark in ten minutes, a leak is indicated. If a very small leak is suspected, wait 30 minutes and observe the vacuum gauge. If a small amount of vacuum is lost, operate the vacuum pump with the gauge valves open for an additional 30 minutes with the heater blower motor on speed 1 to remove any remaining refrigerant from the A/C evaporator core. Then, recheck for loss of vacuum. If a very small leak is suspected, allow the system to sit overnight with vacuum applied and check for vacuum loss the next day. Always remember that a leaking fitting, gauge set, or hose connection will appear as a leaking A/C evaporator core. 7. If a vehicle passes the vacuum leak test and is returned within 60 days for loss of cooling due to no refrigerant charge, look elsewhere in the system for refrigerant leaks, such as the compressor shaft seal or refrigerant line connections. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Auxiliary A/C Evaporator Core Evaporator Core: Service and Repair Auxiliary A/C Evaporator Core REMOVAL 1. Remove the plenum assembly. refer to "Heater Core Case : Service and Repair" See: Heater Core Case/Service and Repair 2. Remove the evaporator/heater core access cover. 1. Remove the ten bolts. 2. Remove the evaporator/heater core access cover. 3. Remove the evaporator core. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Auxiliary A/C Evaporator Core > Page 10128 Evaporator Core: Service and Repair With Manual A/C Spring Lock Coupling Disconnect Tool Set Spring Lock Coupling Disconnect Tool (5/8 Inch) Spring Lock Coupling Spring Lock Coupling Special Tools REMOVAL NOTE: Whenever an A/C evaporator is replaced, it will he necessary to replace the suction accumulator/drier. Before replacing an A/C evaporator core within the warranty for suspected refrigerant leaks, it is mandatory that an on-vehicle leak test be performed. 1. Recover the refrigerant from the system. Refer to: "Heating and Air Conditioning : Service and Repair" See: Service and Repair 2. Drain the radiator. Refer to: "Engine, Cooling and Exhaust : Cooling System : Service and Repair" See: Engine, Cooling and Exhaust/Cooling System/Service and Repair 3. Remove the instrument panel. Refer to: "Body and Frame : Interior Trim : Dash Board : Service and Repair" See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Auxiliary A/C Evaporator Core > Page 10129 4. Disconnect the heater water hoses at the heater core. 5. Fit Spring Lock Coupling Disconnect Tool to the condenser lines so that the spring lock coupling tool can enter the cage opening to release the A/C tube lock coupling spring. 6. Push the tool into the cage opening to release the female fitting from the A/C tube lock coupling spring. 7. Pull the spring lock coupling fittings apart. 8. Remove the RH A/C plenum demister adapter. 1. Remove the screw. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Auxiliary A/C Evaporator Core > Page 10130 2. Remove the RH A/C plenum demister adapter. 9. Remove the heater core outlet bracket. 1. Remove the screws. 2. Remove the bracket. 10. Remove the plenum assembly top. 1. Remove the 14 screws. 2. Remove the plenum assembly top. 11. Remove the A/C evaporator core from the assembly. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Auxiliary A/C Evaporator Core > Page 10131 1. Install the A/C evaporator core. 2. Install the plenum assembly top. 1. Position the plenum assembly top. 2. Install the 14 screws. 3. Install the heater core bracket. 1. Position the bracket. 2. Install the screws. 4. Install the demister. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Auxiliary A/C Evaporator Core > Page 10132 5. Check for a missing or damaged A/C tube lock coupling spring. A damaged spring can be removed with a small hooked wire. Install a new spring if the old one is damaged or missing. 6. Clean the fittings. 7. On the (A) female spring lock coupling, check the inside of each fitting for scratches, corrosion or debris from deteriorated (B) O-rings. - Remove any surface residue from the inside of the coupling by polishing with 400-grit emery cloth (or equivalent). Polish the surface by using a twisting motion so that any scratches made will not cross the O-rings sealing surface. Finish polishing with 600-grit emery cloth or equivalent. Remove all polishing residue from the fitting with a lint free cloth. 8. Use the (A) Plastic O-ring Tool supplied with the O-rings kit or equivalent to remove the (B) O-rings seals from the male fitting. NOTE: Do not use metal O-rings tools. They can cause axial scratches across the O-rings grooves resulting in refrigerant leakage. 9. Install the O-rings seals. Lubricate new O-rings seals. - Use Motorcraft Refrigerant Oil YN-12b, F2AZ-19577-AC or equivalent meeting Ford specification WSH-M1C231-B to lubricate seals. NOTE: Use only specified O-rings seals. Use of any O-rings seal other than the one specified may allow the connection to leak intermittently during vehicle operation. 10. Lubricate the male fitting and the O-rings seals, and the inside of the female fitting. - Use Motorcraft Refrigerant Oil YN-12b, F2AZ-19577-AC or equivalent meeting Ford specification WSH-M1C231-B. 11. Install a plastic indicator ring into cage opening if an indicator ring is to be used. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Auxiliary A/C Evaporator Core > Page 10133 12. Fit the female fitting to the male fitting and push with a twisting motion until the garter spring snaps over the flared end of the female fitting. NOTE: If a plastic indicator ring is used, it will snap out of the cage opening when the coupling is connected to indicate engagement. 13. If an indicator ring is not used, check the coupling engagement by making sure the garter spring is over the flared end of the fitting. 14. Connect the heater core hoses. 15. Install the instrument panel. Refer to: "Body and Frame : Interior Trim : Dash Board : Service and Repair" See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 16. Fill the radiator. Refer to: "Engine, Cooling and Exhaust : Cooling System : Service and Repair" See: Engine, Cooling and Exhaust/Cooling System/Service and Repair 17. Charge the A/C system. Refer to: "Heating and Air Conditioning : Service and Repair" See: Service and Repair Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Page 10134 Evaporator Core: Tools and Equipment Spring Lock Coupling Disconnect Tool Set Spring Lock Coupling Disconnect Tool (5/8 Inch) Spring Lock Coupling Spring Lock Coupling Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations Expansion Block/Orifice Tube: Locations The A/C evaporator core orifice is located in the condenser to evaporator tube. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 10138 Expansion Block/Orifice Tube: Description and Operation NOTE: The A/C evaporator core orifice is replaced as an assembly and should also be replaced whenever the A/C compressor is replaced. The A/C evaporator core orifice, located in the condenser to evaporator tube, is the restriction in the refrigerant system that creates the pressure drop necessary for cooling by metering the flow of liquid refrigerant into the A/C evaporator core. The inlet filter screen acts as a strainer for the liquid refrigerant flowing through the A/C evaporator core orifice. O-ring prevent the high-pressure liquid refrigerant from bypassing the A/C evaporator core orifice. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 10139 Expansion Block/Orifice Tube: Service and Repair Broken Orifice Tube Extractor Fixed Orifice Tube Special Tools REMOVAL CAUTION: Do not attempt to remove the A/C evaporator core orifice with pliers or to twist or rotate the orifice in the liquid line. To do so will break the fixed orifice tube body in the discharge line. Use only the recommended tool. NOTE: The A/C evaporator core orifice should be replaced whenever an A/C compressor is replaced for internal damage. 1. Remove the condenser to evaporator tube. 2. Engage (A) Fixed Orifice Tube Remover/Replacer with the two (B) A/C evaporator core orifice tangs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 10140 3. Hold the tool T-handle and turn the tool nut against the liquid line until the A/C evaporator core orifice is pulled free. 4. If the A/C evaporator core orifice breaks in the liquid line, remove it as follows: 1. Insert the screw end of Broken Orifice Tube Extractor into the liquid tine. 2. Thread the screw end of the tool into the center of the A/C evaporator core orifice brass tube and pull from the liquid line. 3. If only the brass center tube is removed, repeat the process to remove the A/C evaporator core orifice body. INSTALLATION 1. Lubricate the A/C evaporator core orifice O-ring. ^ Use Motorcraft YN-12b Refrigerant Oil F2AZ-19577-AC or equivalent meeting Ford specification WSH-M1C231-B. 2. Place the (B) A/C evaporator core orifice in (A) Fixed Orifice Tube Remover/Replacer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 10141 3. Insert the A/C evaporator core orifice into the discharge line until it seats at the stop. 4. Remove Fixed Orifice Tube Remover/Replacer from the A/C evaporator core orifice. 5. Install the evaporator to condenser tube. 6. Leak test the A/C system. 7. Evacuate and charge the system. See: Service and Repair/Evacuation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 10142 Expansion Block/Orifice Tube: Tools and Equipment Broken Orifice Tube Extractor Fixed Orifice Tube Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Locations > Page 10146 Expansion Valve: Description and Operation A/C EVAPORATOR EXPANSION VALVE An A/C evaporator expansion valve automatically regulates the flow of refrigerant into the A/C evaporator core in the auxiliary heater and air conditioner assembly. It is also the dividing point in the system between high and low pressure refrigerant. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 10155 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 10156 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 10162 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 10163 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 97-19-11 > Sep > 97 > Heater Core - On Car Pressure Test For Warranty Claim Heater Core: All Technical Service Bulletins Heater Core - On Car Pressure Test For Warranty Claim Article No. 97-19-11 09/15/97 COOLING SYSTEM - "ON-VEHICLE" HEATER CORE PRESSURE TEST REQUIRED FOR WARRANTY CLAIM FORD: 1993-97 PROBE, THUNDERBIRD 1993-98 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1995-98 CONTOUR LINCOLN-MERCURY: 1993-97 COUGAR 1993-98 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-98 MYSTIQUE LIGHT TRUCK: 1993-98 ECONOLINE, EXPLORER, F SUPER DUTY, F-150-350 SERIES, RANGER, VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: An "On-Vehicle" heater core pressure test is required before replacing any heater core within the warranty period. ACTION: Perform the "On-Vehicle" heater core pressure test by referring to the following heater core leak test procedure. HEATER CORE LEAK TEST PROCEDURE Use the heater core pressure test to determine if the heater core is leaking. Symptoms associated with a leaking heater core include: ^ Engine coolant leaking into the passenger compartment ^ Engine coolant blown onto the windshield during defrost operation ^ Engine coolant odor inside the passenger compartment 1. Partially drain cooling system. 2. Disconnect both heater core hoses. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 97-19-11 > Sep > 97 > Heater Core - On Car Pressure Test For Warranty Claim > Page 10168 3. Attach two (2) pieces of heater hose to the heater core inlet and outlet tubes and clamp (Figure 1). 4. Install Plug (part of 014-R1072) into one (1) heater hose and clamp (Figure 1). 5. Fill heater core and hoses with water. 6. Install Adapter (part of 0144-R1072) into other heater hose and clamp (Figure 1). 7. Attach Radiator/Heater Core Pressure Tester (014-R1072) to Adapter (part of 014-R1072) (Figure 1). 8. Close the bleed valve and the tester and pump air into the heater core until 241 kPa (35 psi) is reached on the tester gauge. 9. Observe the gauge after 3 minutes. The pressure should not drop. If the pressure does drop, there is a leak. Check the hose connections and retest if you find a leak. 10. Replace heater core if pressure drops and hose connections do not leak. 11. Do not replace heater core if pressure does not drop. Pressure test engine cooling system for leaks elsewhere. 12. Reconnect heater core and refill cooling system after all necessary repairs. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208999, 290000, 402000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Core: > 97-19-11 > Sep > 97 > Heater Core - On Car Pressure Test For Warranty Claim Heater Core: All Technical Service Bulletins Heater Core - On Car Pressure Test For Warranty Claim Article No. 97-19-11 09/15/97 COOLING SYSTEM - "ON-VEHICLE" HEATER CORE PRESSURE TEST REQUIRED FOR WARRANTY CLAIM FORD: 1993-97 PROBE, THUNDERBIRD 1993-98 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1995-98 CONTOUR LINCOLN-MERCURY: 1993-97 COUGAR 1993-98 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-98 MYSTIQUE LIGHT TRUCK: 1993-98 ECONOLINE, EXPLORER, F SUPER DUTY, F-150-350 SERIES, RANGER, VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: An "On-Vehicle" heater core pressure test is required before replacing any heater core within the warranty period. ACTION: Perform the "On-Vehicle" heater core pressure test by referring to the following heater core leak test procedure. HEATER CORE LEAK TEST PROCEDURE Use the heater core pressure test to determine if the heater core is leaking. Symptoms associated with a leaking heater core include: ^ Engine coolant leaking into the passenger compartment ^ Engine coolant blown onto the windshield during defrost operation ^ Engine coolant odor inside the passenger compartment 1. Partially drain cooling system. 2. Disconnect both heater core hoses. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Core: > 97-19-11 > Sep > 97 > Heater Core - On Car Pressure Test For Warranty Claim > Page 10174 3. Attach two (2) pieces of heater hose to the heater core inlet and outlet tubes and clamp (Figure 1). 4. Install Plug (part of 014-R1072) into one (1) heater hose and clamp (Figure 1). 5. Fill heater core and hoses with water. 6. Install Adapter (part of 0144-R1072) into other heater hose and clamp (Figure 1). 7. Attach Radiator/Heater Core Pressure Tester (014-R1072) to Adapter (part of 014-R1072) (Figure 1). 8. Close the bleed valve and the tester and pump air into the heater core until 241 kPa (35 psi) is reached on the tester gauge. 9. Observe the gauge after 3 minutes. The pressure should not drop. If the pressure does drop, there is a leak. Check the hose connections and retest if you find a leak. 10. Replace heater core if pressure drops and hose connections do not leak. 11. Do not replace heater core if pressure does not drop. Pressure test engine cooling system for leaks elsewhere. 12. Reconnect heater core and refill cooling system after all necessary repairs. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208999, 290000, 402000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 10175 Heater Core: Specifications Heater Core Bracket Screws ....................................................................................................................................................... 1.5-2.5 N.m (12-22 Lb/In) Heater Core Outlet Bracket Screws ............................................................................................................................................. 1.5-2.5 N.m (13-22 Lb/In) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Auxiliary Heater Core: Description and Operation Auxiliary The auxiliary A/C and heating system uses a rear-mounted heater core. The rear-mounted heater core operates the same as the front-mounted heater core. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Auxiliary > Page 10178 Heater Core: Description and Operation General Information Heater Core The heater core consists of fins and tubes arranged to extract heat from the engine coolant and transfer it to air passing through the heater core. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Page 10179 Heater Core: Testing and Inspection Digital Multimeter Set, A/C Fittings R-134a Automatic Calibration Halogen Leak Detector Radiator/Heater Core Pressure Tester Special Tools HEATER CORE WARNING: CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED AREA SUCH AS A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE CLOSED AREA. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores are good and should not have been replaced. If a heater core leak is suspected, the heater core should be tested as per Plugged Heater Core procedures before pressure testing the heater core. Perform a system inspection by checking the heater system thoroughly as follows: 1. Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A coolant leak in the heater water hose could follow the heater core tube to the heater core and appear as a leak in the heater core. 2. Check the integrity of the heater water hose clamps. 3. Spring-type clamps are installed as original equipment. Use of non-specification clamps can cause leakage at the heater water hose connection Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Page 10180 and damage the heater core. PLUGGED HEATER CORE WARNING: THE HEATER CORE INLET HOSE WILL BECOME TOO HOT TO HANDLE IF THE SYSTEM IS WORKING CORRECTLY. Check to see that the engine coolant is at the proper level. Start the engine and turn on the heater. When the engine coolant reaches operating temperature, feel the heater core outlet hose to see if it is hot. If it is not hot, the heater core may have an air pocket or may be plugged, or the thermostat is not working properly. Pressure Test Use Radiator/Heater Core Pressure Tester to perform the pressure test. 1. Drain the coolant from the cooling system. NOTE: Due to space limitations, a bench test may be necessary for pressure testing. 2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater water hose, approximately 101 mm (4 inches) long on each heater core tube. 4. Fill the heater core and heater water hoses with water and install plug and adapter from Radiator/Heater Core Pressure Tester in the heater water hose ends. Secure the heater water hoses, plug and adapter with hose clamps tightened to specification. 5. Attach the pump and gauge assembly from Radiator/Heater Core Pressure Tester to the adapter. 6. Close the bleed valve at the base of the gauge and pump 241 kPa (35 psi) of air pressure into the heater core. 7. Observe the pressure gauge for a minimum of three minutes. 8. If the pressure drops, check the heater water hose connections to the core tubes for leaks. If the heater water hoses do not leak, test the heater core as follows: 1. Drain all coolant from the heater core. 2. Remove the heater core from the A/C evaporator housing. 3. Connect the 101 mm (4 inches) test heater water hoses with plug and adapter to the core tubes. Then connect Radiator/Heater Core Pressure Tester to the adapter. 4. Apply 241 kPa (35 psi) of air pressure to the heater core. Submerge the heater core in water. 5. If a leak is observed, service or replace the heater core. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Back Flushing-Heater Core Heater Core: Service and Repair Back Flushing-Heater Core 1. Release the pressure in the cooling system by slowly turning the radiator cap one turn counterclockwise. When the pressure is released, remove the radiator cap. WARNING: DO NOT OPEN THE COOLING SYSTEM WHILE IT IS HOT OR WHILE THE ENGINE IS RUNNING. 2. Partially drain the cooling system. 3. Remove the two heater hoses from the engine. a. Slide the (A) hose clamp away from the end of the (B) heater inlet hose. b. Remove the heater inlet hose. c. Slide the (A) hose clamp away from the end of the (By heater outlet hose. d. Remove the heater outlet hose. 4. Use cooling system Flush-All, Flush Kit Hardware Package and Drain Kit to back flush heater core with Ford Premium Cooling System Flush F1AZ-19A503-A or equivalent meeting Ford specification ESR-M14P7-A. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Back Flushing-Heater Core > Page 10183 5. Install the heater hoses. a. Position the heater inlet hose. b. Slide the (A) hose clamp toward the end of the (B) heater inlet hose. c. Position the heater outlet hose. d. Slide the (C) hose clamp toward end of (D) heater outlet hose. 6. Fill the cooling system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Back Flushing-Heater Core > Page 10184 Heater Core: Service and Repair Removal and Installation Front REMOVAL 1. Disconnect the battery ground cable. 2. Drain the radiator. Refer to: "Engine, Cooling and Exhaust : Cooling System : Service and Repair" See: Engine, Cooling and Exhaust/Cooling System/Service and Repair 3. Remove the instrument panel. Refer to: "Body and Frame : Interior Trim : Dash Board : Service and Repair" See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 4. Compress the holding tabs and disconnect the heater water hoses at the heater core. 5. Remove the A/C plenum demister adapter. 1. Remove the screw. 2. Remove the A/C plenum demister adapter. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Back Flushing-Heater Core > Page 10185 6. Disconnect the vacuum line. 7. Remove the heater core bracket. 1. Remove the two screws. 2. Remove the bracket. 8 Remove the plenum assembly top. 1. Remove the 13 screws. 2. Remove the plenum assembly top. 9. Remove the blend door assembly from the case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Back Flushing-Heater Core > Page 10186 10. Remove the heater core. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Auxiliary REMOVAL Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Back Flushing-Heater Core > Page 10187 1. Remove the plenum assembly. Refer to: "Heater Core Case : Service and Repair" See: Heater Core Case/Service and Repair 2. Remove the evaporator/heater core access cover. 1. Remove the ten bolts. 2. Remove the evaporator/heater core access cover. 3. Remove the heater core. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Page 10188 Heater Core: Tools and Equipment Digital Multimeter Set, A/C Fittings R-134a Automatic Calibration Halogen Leak Detector Radiator/Heater Core Pressure Tester Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Specifications Heater Core Case: Specifications Plenum Top Screws ............................................................................................................................ ......................................... 1.5-2.5 N.m (13-22 Lb/In) Plenum Assembly Nuts (Engine Nuts) .............................................................................................................................................. 4-6 N.m (36-53 Lb/In) Plenum Assembly Nuts (Passenger Nuts) ......................................................................................................................................... 4-6 N.m (36-53 Lb/In) A/C Plenum Demister Adapter Screw ............................................................................................................................................... 2-3 N.m (18-27 Lb/In) Demister Screw ................................................................................................................................... .............................................. 2-3 N.m (20-30 Lb/In) Plenum Mounting Bolts .............................................................................................................................................................. 5.2-6.7 N.m (46-64 Lb/In) Evaporator/Heater Core Access Cover Bolts .................................................................................................................................... 2-3 N.m (18-26 Lb/In) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Service and Repair > Auxiliary A/C and Heating System Heater Core Case: Service and Repair Auxiliary A/C and Heating System Heater Hose Disconnect Tool Special Tools REMOVAL 1. Recover refrigerant from the A/C system. Refer to: "Heating and Air Conditioning : Service and Repair" See: Service and Repair 2. Remove the LH quarter trim panel. Refer to: "Body and Frame : Interior Trim : Trim Panel : Service and Repair" See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair 3. Remove the wiring harness from the plenum assembly. - Disconnect the necessary electrical connectors. 4. Disconnect the heater core hoses. - Use Heater Hose Disconnect Tool. - Cap the heater core hoses. 5. Remove the evaporator case drain hose. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Service and Repair > Auxiliary A/C and Heating System > Page 10194 6. Disconnect the A/C lines from the A/C evaporator expansion valve. 7. Remove the A/C outlet duct. 1. Remove the pushpin. 2. Remove the A/C outlet duct. 8. Remove the plenum assembly. 1. Remove the three bolts. 2. Remove the plenum assembly. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Service and Repair > Auxiliary A/C and Heating System > Page 10195 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Service and Repair > Auxiliary A/C and Heating System > Page 10196 Heater Core Case: Service and Repair With Air Conditioning Spring Lock Coupling Disconnect Tool Set Spring Lock Coupling Disconnect Tool (5/8 Inch) Spring Lock Coupling Spring Lock Coupling Special Tools REMOVAL 1. Disconnect the battery ground cable. 2. Recover the refrigerant from the system. Refer to: "Heating and Air Conditioning : Service and Repair" See: Service and Repair 3. Drain the radiator. Refer to: "Engine, Cooling and Exhaust : Cooling System : Service and Repair" See: Engine, Cooling and Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Service and Repair > Auxiliary A/C and Heating System > Page 10197 Exhaust/Cooling System/Service and Repair 4. Remove the instrument panel. Refer to: "Body and Frame : Interior Trim : Dash Board : Service and Repair" See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 5. Disconnect the heater water hoses at the heater core. 6. Fit Spring Lock Coupling Disconnect Tool to the condenser lines so that the spring lock coupling tool can enter the cage opening to release the A/C tube lock coupling spring. 7. Push the tool into the cage opening to release the female fitting from the A/C tube lock coupling spring. 8. Pull the spring lock coupling fittings apart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Service and Repair > Auxiliary A/C and Heating System > Page 10198 9. Remove the two plenum assembly nuts (engine side). 10. Disconnect the A/C vacuum hose from the A/C vacuum check valve. 11. Remove the two plenum assembly nuts (interior). 12. Remove the plenum assembly. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Service and Repair > Auxiliary A/C and Heating System > Page 10199 1. Position the plenum assembly and install the two nuts. 2. Connect the A/C vacuum hose from the A/C vacuum check valve. 3. Install the two nuts on the engine side. 4. Check for a missing or damaged A/C tube lock coupling spring. A damaged spring can be removed with a small hooked wire. Install a new spring if the old one is damaged or missing. 5. Clean the fittings. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Service and Repair > Auxiliary A/C and Heating System > Page 10200 6. On the (A) female spring lock coupling, check the inside of each fitting for scratches, corrosion or debris from deteriorated (B) O-rings. - Remove any surface residue from the inside of the coupling by polishing with 400-grit emery cloth (or equivalent). Polish the surface by using a twisting motion so that any scratches made will not cross the O-ring sealing surface. Finish polishing with 600-grit emery cloth or equivalent. Remove all polishing residue from the fitting with a lint free cloth. 7. Use (A) plastic O-ring tool supplied in O-ring kit to remove the (B) O-ring seals from the male fitting. NOTE: Do not use metal O-ring tools. They can cause axial scratches across the O-rings grooves, resulting in refrigerant leakage. 8. Install the O-rings seals. Lubricate the new O-rings seals. - Use Motorcraft Refrigerant Oil YN-12b, F2AZ-19577-AC or equivalent meeting Ford specification WSH-M1C231-B to lubricate seals. NOTE: Use only specified O-rings seals. Use of any O-rings seal other than the one specified may allow the connection to leak intermittently during vehicle operation. 9. Lubricate the male fitting and the O-rings seals, and the inside of the female fitting. - Use Motorcraft Refrigerant Oil YN-12b, F2AZ-19577-AC or equivalent meeting Ford specification WSH-M1C231-B. 10. Install a plastic indicator ring into cage opening if an indicator ring is to be used. 11. Fit the female fitting to the male fitting and push with a twisting motion until the garter spring snaps over the flared end of the female fitting. NOTE: If a plastic indicator ring is used, it will snap out of the cage opening when the coupling is connected to indicate engagement. 12. If an indicator ring is not used, check the coupling engagement by making sure the garter spring is over the flared end of the fitting. 13. Connect the heater core hoses. 14. Install the instrument panel. Refer to: "Body and Frame : Interior Trim : Dash Board : Service and Repair" See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 15. Fill the radiator. Refer to: "Engine, Cooling and Exhaust : Cooling System : Service and Repair" See: Engine, Cooling and Exhaust/Cooling System/Service and Repair Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Service and Repair > Auxiliary A/C and Heating System > Page 10201 16. Connect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal derive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. 17. Charge the A/C system. Refer to: "Heating and Air Conditioning : Service and Repair" See: Service and Repair Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Service and Repair > Page 10202 Heater Core Case: Tools and Equipment Spring Lock Coupling Disconnect Tool Set Spring Lock Coupling Disconnect Tool (5/8 Inch) Spring Lock Coupling Spring Lock Coupling Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 10211 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 10212 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 10218 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 10219 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes Service Tip. Heater Hose: All Technical Service Bulletins Rear Air Conditioning Lines/Tubes - Service Tip. Article No. 97-14-20 07/07/97 ^ AIR CONDITIONING - REAR AUXILIARY UNDERBODY A/C LINES AND TUBES - SERVICE TIP ^ COOLING SYSTEM - REAR AUXILIARY UNDERBODY HEATER LINES AND TUBES SERVICE TIP LIGHT TRUCK: 1997 EXPEDITION ISSUE: Additional information has been released by Ford Motor Company regarding the servicing of the underbody tubes and hoses for the rear auxiliary A/C and heater systems. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes Service Tip. > Page 10224 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes Service Tip. > Page 10225 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes Service Tip. > Page 10226 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes Service Tip. > Page 10227 ACTION: When servicing the underbody tubes and hoses for the rear auxiliary A/C and heater, refer to the following illustrations (Figures 1-4) to determine correct part number and part locations. Refer to the 1997 Expedition Workshop Manual for all part removal and installation procedures. PART NUMBER PART NAME F75Z-18663-KA Front Heater Outlet Tube Kit F75Z-18696-KA Front Heater Inlet Tube Kit F75Z-18663-LA Rear Heater Outlet Tube Kit F75Z-18696-LA Hear Heater Inlet Tube Kit F75Z-19867-KA Rear A/C Suction Tube Kit F75Z-19835-JA Rear A/C Liquid Tube Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes Service Tip. > Page 10228 OASIS CODES: 208100, 208200, 208999, 290000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes - Service Tip. Heater Hose: All Technical Service Bulletins Rear Air Conditioning Lines/Tubes - Service Tip. Article No. 97-14-20 07/07/97 ^ AIR CONDITIONING - REAR AUXILIARY UNDERBODY A/C LINES AND TUBES - SERVICE TIP ^ COOLING SYSTEM - REAR AUXILIARY UNDERBODY HEATER LINES AND TUBES SERVICE TIP LIGHT TRUCK: 1997 EXPEDITION ISSUE: Additional information has been released by Ford Motor Company regarding the servicing of the underbody tubes and hoses for the rear auxiliary A/C and heater systems. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes - Service Tip. > Page 10234 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes - Service Tip. > Page 10235 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes - Service Tip. > Page 10236 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes - Service Tip. > Page 10237 ACTION: When servicing the underbody tubes and hoses for the rear auxiliary A/C and heater, refer to the following illustrations (Figures 1-4) to determine correct part number and part locations. Refer to the 1997 Expedition Workshop Manual for all part removal and installation procedures. PART NUMBER PART NAME F75Z-18663-KA Front Heater Outlet Tube Kit F75Z-18696-KA Front Heater Inlet Tube Kit F75Z-18663-LA Rear Heater Outlet Tube Kit F75Z-18696-LA Hear Heater Inlet Tube Kit F75Z-19867-KA Rear A/C Suction Tube Kit F75Z-19835-JA Rear A/C Liquid Tube Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > 97-14-20 > Jul > 97 > Rear Air Conditioning Lines/Tubes - Service Tip. > Page 10238 OASIS CODES: 208100, 208200, 208999, 290000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Page 10239 Heater Hose: Specifications Hose Clamp ......................................................................................................................................... ........................................ 1.6-2.2 N.m (17-22 Lb/In) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Page 10240 Heater Hose: Description and Operation The supply lines are one-piece tubes that are secured to the underbody of the vehicle. Replacement kits are only available with multiple-piece lines for ease of installation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Outlet Tube Heater Hose: Service and Repair Front Outlet Tube Heater Hose Disconnect Tool Special Tools REMOVAL 1. Drain the cooling system. 2. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 3. Remove the RH front fender splash shield. 1. Remove the five screws. 2. Remove the three pushpins. 3. Remove the front fender splash shield. 4. Remove the four tube brackets. 1. Remove the nuts. 2. Remove the bracket by inserting a screw driver in the bracket slot and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the tubes. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 10243 5. Disconnect the heater outlet tube from the outlet hose. ^ Use Heater Hose Disconnect Tool to disconnect the hose. 6. Disconnect the front auxiliary heater outlet tube from the rear auxiliary heater outlet tube. 1. Remove the nut. 2. Disconnect the line. 7. Cut the heater outlet tube in the positions shown. 8. Remove and discard the cut sections. INSTALLATION 1. Install the heater outlet tube. ^ In stall the end with blue tape over the frame. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 10244 2. Install the heater outlet tube. ^ Install the end with red tape over the frame and the end with yellow tape between the frame and the body vertical flange. 3. Connect the heater water outlet tubes. 1. Connect the fitting. 2. Loosely install the nut. 4. Install the heater water outlet tube. ^ Install the tube through the wheel opening. 5. Connect the heater water outlet tubes. 1. Connect the fitting. 2. Loosely install the nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 10245 6. Tighten the two peanut fittings. 7. Install the tube brackets. 1. Position the bracket. 2. Install the nut. ^ Snap the tube into the bracket. CAUTION: Insure that clearance exists between the frame and the tubes. NOTE: The bracket must be positioned equally between the white location marks on the tube. 8. Connect heater water outlet tube to engine heater outlet hose. 9. Install the front fender splash shield. 10. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 10246 11. Fill the cooling system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 10247 Heater Hose: Service and Repair Rear Inlet Tube Heater Hose Disconnect Tool Special Tools REMOVAL 1. Drain the cooling system. 2. Remove the quarter trim panel access cover. 3. Disconnect the heater inlet hose. ^ Use Heater Hose Disconnect Tool to disconnect the inlet hose. 4. Remove the auxiliary A/C line grommet retainer. 1. Remove the bolts. 2. Remove the retainer. 5. Remove the spare tire. 6. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 10248 7. Lower the muffler heat shield. 1. Remove the two front bolts. 2. Lower the heat shield. 8. Remove the four tube brackets. 1. Remove the nuts. 2. Remove the bracket by inserting a screw driver in the bracket slot and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the tubes. 9. Cut the tube in the positions shown. 10. Remove and discard the cut sections. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 10249 1. Install the heater inlet tube. ^ Install the end with green tape over the axle between the frame and body. 2. Connect the heater inlet tube to the front auxiliary line. 1. Connect the inlet tube. 2. Loosely install the nut. 3. Install the heater inlet tube. ^ Install the end with blue tape between the frame crossmember and the floor pan. 4. Connect the heater inlet tubes. 1. Connect the fittings. 2. Loosely install the nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 10250 5. Install the heater inlet tube. ^ In stall the end with red tape between the frame and the body. 6. Connect the heater tubes. 1. Connect the fittings. 2. Loosely install the nut. 7. Install the heater inlet rube. ^ Install the end with green tape through the floor opening. 8. Connect the heater inlet tubes. 1. Connect the fittings. 2. Loosely install the nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 10251 9. Tighten the four peanut fittings. 10. Install the tube brackets. 1. Position the bracket. 2. Install the nut. ^ Snap the tube into the bracket. NOTE: The bracket must be positioned equally between the white location marks on the tube. 11. Install the muffler heat shield. 1. Position the shield. 2. Install the nuts 12. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. 13. Install the grommet tube seal and retainer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 10252 NOTE: Insure that the tubes are entering through the center of the floor opening and that the retainer locating marks are positioned correctly. 14. Connect the heater inlet hose to the auxiliary heater core. 15. Install the quarter trim access panel. 16. Install the spare tire. 17. Fill the cooling system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 10253 Heater Hose: Service and Repair Rear Outlet Tube Heater Hose Disconnect Tool Special Tools REMOVAL 1. Drain the cooling system. 2. Remove the quarter trim panel access cover. 3. Disconnect the heater outlet hose. ^ Use Heater Hose Disconnect Tool to disconnect the outlet hose. 4. Remove the auxiliary A/C line grommet retainer. 1. Remove the bolts. 2. Remove the retainer. 5. Remove the spare tire. 6. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 10254 7. Lower the muffler heat shield. 1. Remove the two front bolts. 2. Lower the heat shield. 8. Remove the four tube brackets. 1. Remove the nuts. 2. Remove the bracket by inserting a screw driver in the bracket slot and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off. 9. Cut the tube in the positions shown. 10. Remove and discard the cut sections. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 10255 1. Install the heater outlet tube. ^ Install the end with blue tape over the axle between the frame and the body. 2. Connect the heater outlet tube to the front auxiliary tube. 1. Connect the fittings. 2. Loosely install the nut. 3. Install the heater outlet tube. ^ Install the end with red tape between the frame and the crossmember. 4. Connect the heater outlet tubes. 1. Connect the fittings. 2. Loosely install the nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 10256 5. Install the heater outlet tube. ^ Install the end with blue tape between the frame and body. 6. Connect the heater outlet tubes. 1. Connect the fittings. 2. Loosely install the nut. 7. Install the heater outlet tube. ^ Install the end with the hose through the floor opening. 8. Tighten the four peanut fittings. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 10257 9. Install the tube brackets. 1. Position the bracket. 2. Install the nut. ^ Snap the tube into the bracket. NOTE: The bracket must be positioned equally between the white location marks on the tube. 10. Install the muffler heat shield. 1. Position the shield. 2. Install the nuts. 11. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. 12. Install the grommet tube seal and retainer. NOTE: Insure that the tubes are entering through the center of the floor opening and that the retainer locating marks are positioned correctly. 13. Connect the heater outlet hose to the auxiliary heater core. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 10258 14. Install the quarter trim access panel. 15. Install the spare tire. 16. Fill the cooling system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 10259 Heater Hose: Service and Repair Removal and Installation REMOVAL 1. Drain the radiator. 2. Disconnect the heater outlet hose at the engine. 3. Disconnect the heater inlet hose at the engine. 1. Loosen the hose clamp. 2. Disconnect the heater inlet hose. 4. Compress the holding tabs and disconnect the heater water hoses at the heater core. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Outlet Tube > Page 10260 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation High Pressure Safety Valve HVAC: Description and Operation An A/C compressor pressure relief valve is incorporated in the compressor's A/C manifold and tube to relieve unusually high refrigerant system discharge pressure buildups (3241 kPa [470 psi] and above). This prevents damage to the A/C compressor and other system components and avoids total refrigerant loss by closing after the excessive pressure has been relieved. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Rear Air Conditioning Lines/Tubes - Service Tip. Hose/Line HVAC: Technical Service Bulletins Rear Air Conditioning Lines/Tubes - Service Tip. Article No. 97-14-20 07/07/97 ^ AIR CONDITIONING - REAR AUXILIARY UNDERBODY A/C LINES AND TUBES - SERVICE TIP ^ COOLING SYSTEM - REAR AUXILIARY UNDERBODY HEATER LINES AND TUBES SERVICE TIP LIGHT TRUCK: 1997 EXPEDITION ISSUE: Additional information has been released by Ford Motor Company regarding the servicing of the underbody tubes and hoses for the rear auxiliary A/C and heater systems. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Rear Air Conditioning Lines/Tubes - Service Tip. > Page 10268 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Rear Air Conditioning Lines/Tubes - Service Tip. > Page 10269 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Rear Air Conditioning Lines/Tubes - Service Tip. > Page 10270 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Rear Air Conditioning Lines/Tubes - Service Tip. > Page 10271 ACTION: When servicing the underbody tubes and hoses for the rear auxiliary A/C and heater, refer to the following illustrations (Figures 1-4) to determine correct part number and part locations. Refer to the 1997 Expedition Workshop Manual for all part removal and installation procedures. PART NUMBER PART NAME F75Z-18663-KA Front Heater Outlet Tube Kit F75Z-18696-KA Front Heater Inlet Tube Kit F75Z-18663-LA Rear Heater Outlet Tube Kit F75Z-18696-LA Hear Heater Inlet Tube Kit F75Z-19867-KA Rear A/C Suction Tube Kit F75Z-19835-JA Rear A/C Liquid Tube Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Rear Air Conditioning Lines/Tubes - Service Tip. > Page 10272 OASIS CODES: 208100, 208200, 208999, 290000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 10273 Hose/Line HVAC: Specifications Tube Bracket Nut ................................................................................................................................. ........................................... 10-14 N.m (8-10 Lb/Ft) A/C Line Bracket Nuts ......................................................................................................................... ....................................... 6.8-9.2 N.m (61-82 Lb/In) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 10274 Hose/Line HVAC: Description and Operation The supply lines are one-piece tubes that are secured to the underbody of the vehicle. Replacement kits are only available with multiple-piece lines for ease of installation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Condenser to Evaporator Line Hose/Line HVAC: Service and Repair Condenser to Evaporator Line Spring Lock Coupling Disconnect Tool Set Spring Lock Coupling Disconnect Tool (5/8 Inch) Spring Lock Coupling Spring Lock Coupling Special Tools REMOVAL 1. Disconnect the battery ground cable. 2. Recover the refrigerant from the system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Condenser to Evaporator Line > Page 10277 3. Remove the line clip at the evaporator connection. 4. Fit Spring Lock Coupling Disconnect Tool to the condenser lines so that the spring lock coupling tool can enter the cage opening to release the A/C tube lock coupling spring. 5. Push the tool into the cage opening to release the female fitting from the A/C tube lock coupling spring. 6. Pull the spring lock coupling fittings apart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Condenser to Evaporator Line > Page 10278 7. Disconnect the A/C condenser core lower line. 1. Remove the nut. 2. Disconnect the A/C condenser core lower line. 8. Remove the tube bracket nut. 9. Remove the suction accumulator/drier bracket clamping bolt. 10. Remove the evaporator to condenser tube. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Condenser to Evaporator Line > Page 10279 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Condenser to Evaporator Line > Page 10280 Hose/Line HVAC: Service and Repair A/C Auxiliary Evaporator Hoses Outlet Tube - (5/8 In) REMOVAL 1. Recover the refrigerant from the A/C system. See: Service and Repair/Refrigerant Recovery 2. Remove the quarter trim panel access cover. 3. Disconnect the outlet tube from the underbody line. 1. Remove the nut. 2. Remove the line. 4. Remove the auxiliary A/C line grommet retainer. 1. Remove the bolts. 2. Remove the retainer. 5. Remove the spare tire. 6. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 7. Remove the four tube brackets. 1. Remove the nuts. 2. Remove the bracket by inserting a screw driver in the bracket slot and twisting. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Condenser to Evaporator Line > Page 10281 CAUTION: Pull the bracket off the stud before attempting to pry it off the tubes. 8. Disconnect the (5/8 in) outlet tube peanut fitting. 1. Remove the nut. 2. Disconnect the line. 9. Cut the (5/8 in) outlet tube in four places. 10. Remove and discard the line. INSTALLATION 1. Install the outlet line over frame. ^ Install the end with purple tape in-between frame and body. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Condenser to Evaporator Line > Page 10282 2. Connect the outlet line peanut fitting. 1. Connect the outlet lines. 2. Loosely install the nut. 3. Install the outlet line. ^ Install the end with the purple tape between the frame and body. 4. Connect the outlet line peanut fitting to outlet line over frame. 1. Connect the outlet lines. 2. Loosely install the nut. 5. Install the outlet line over frame. ^ Install the end with yellow tape. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Condenser to Evaporator Line > Page 10283 6. Connect the outlet line peanut fitting to outlet line over frame. ^ Connect the fitting and loosely install the nut. 7. Install the outlet line. ^ Install the end with orange tape between the frame and body near rear wheel opening. 8. Connect the outlet line peanut fitting to outlet line over frame. ^ Connect the fitting and loosely install the nut. 9. Install the outlet line through the floor. ^ Install the end of the tube with no tape through the floor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Condenser to Evaporator Line > Page 10284 10. Connect the peanut fitting to outlet line over frame. ^ Connect the fitting and loosely install the nut. 11. Tighten the five peanut fittings. 12. Install the tube brackets. 1. Position the bracket. 2. Install the nut. ^ Snap the tube into the bracket. NOTE: The bracket must be positioned equally between the white location marks on the tube. 13. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. 14. Connect the outlet tube to the auxiliary evaporator case tube. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Condenser to Evaporator Line > Page 10285 15. Install the grommet tube seal and retainer. NOTE: Insure that the tubes are entering through the center of the floor opening and that the retainer locating marks are positioned correctly. 16. Install the quarter trim access panel. 17. Evacuate and charge the A/C system. See: Service and Repair/Evacuation 18. Install the spare tire. Inlet Tube - (3/8 In) REMOVAL 1. Recover the refrigerant from the A/C system. See: Service and Repair/Refrigerant Recovery 2. Remove the quarter trim panel access cover. 3. Disconnect the inlet tube from the underbody line. 1. Remove the nut. 2. Remove the line. 4. Remove the auxiliary A/C lines grommet retainer. 1. Remove the bolts. 2. Remove the retainer. 5. Remove the spare tire. 6. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Condenser to Evaporator Line > Page 10286 7. Remove the four tube brackets. 1. Remove the nuts. 2. Remove the bracket by inserting a screw driver in the bracket slot and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the tubes. 8. Disconnect the inlet line peanut fitting. 1. Remove the nut. 2. Disconnect the line. 9. Cut the (3/8 in) inlet tube in four places. 10. Remove and discard the line. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Condenser to Evaporator Line > Page 10287 1. Install the inlet tube from the rear of the vehicle over the frame. 2. Connect the inlet tube to the front underbody A/C lines. 1. Connect the inlet tube. 2. Loosely install the nut. 3. Install the inlet tube over the frame. ^ Insert the end with orange tape first. 4. Connect the inlet tubes. 1. Connect the inlet tubes. 2. Loosely install the nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Condenser to Evaporator Line > Page 10288 5. Install the inlet tube. ^ Install the end with yellow tape between the frame and body. 6. Connect the inlet tubes. ^ Connect the fitting and loosely install the nut. 7. Install the inlet tube. ^ Install the end without tape through the floor. 8. Connect the inlet tubes. 1. Connect the line. 2. Loosely install the nut. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Condenser to Evaporator Line > Page 10289 9. Tighten the four peanut fittings. 10. Install the tube brackets. 1. Position the bracket. 2. Install the nut. ^ Snap the tube into the bracket. NOTE: The bracket must be positioned equally between the white location marks on the tube. 11. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. 12. Connect the inlet tube to the auxiliary evaporator case tube. 13. Install the grommet tube seal and retainer. NOTE: Insure that the tubes are entering through the center of the floor opening and that the retainer locating marks are positioned correctly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Condenser to Evaporator Line > Page 10290 14. Install the quarter trim access panel. 15. Evacuate and charge the A/C system. See: Service and Repair/Evacuation 16. Install the spare tire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Condenser to Evaporator Line > Page 10291 Hose/Line HVAC: Service and Repair Outlet Tube - Auxiliary A/C, Front Assembly REMOVAL 1. Recover the refrigerant from the system. See: Service and Repair/Refrigerant Recovery 2. Remove the RH front fender splash shield. 1. Remove the five screws. 2. Remove the three pushpins. 3. Remove the front fender splash shield. 3. Remove the three tube brackets. 1. Remove the nuts. 2. Remove the bracket by inserting a screw driver in the bracket slot and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the tubes. 4. Disconnect the auxiliary outlet tube from the condenser line. 1. Remove the nut. 2. Disconnect the tube. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Condenser to Evaporator Line > Page 10292 5. Disconnect the front auxiliary outlet line from the rear auxiliary tube. 1. Remove the nut. 2. Disconnect the tube. 6. Remove the front auxiliary outlet line. INSTALLATION 1. Install the front auxiliary outlet tube. 2. Connect the front auxiliary outlet line to the rear auxiliary line. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Condenser to Evaporator Line > Page 10293 3. Connect the front auxiliary outlet tube to the condenser line. 1. Connect the tube. 2. Install the nut. 4. Install the tube brackets. 1. Position the bracket. 2. Install the nut. ^ Snap the tube into the bracket. NOTE: The bracket must be positioned equally between the white location marks on the tube. 5. Install the front fender splash shield. 6. Lower the vehicle. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. 7. Evacuate and charge the A/C system. See: Service and Repair/Evacuation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Page 10294 Hose/Line HVAC: Tools and Equipment Spring Lock Coupling Disconnect Tool Set Spring Lock Coupling Disconnect Tool (5/8 Inch) Spring Lock Coupling Spring Lock Coupling Heater Hose Disconnect Tool Heater Hose Disconnect Tool Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Page 10295 Heater Hose Disconnect Tool Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation Receiver Dryer: Description and Operation NOTE: Replacement of the suction accumulator/drier is necessary if there is moisture in the system, the system is open for an extended amount of time or any time a major component is replaced. Major components include: ^ A/C compressor. ^ A/C condenser core. ^ The A/C evaporator core. ^ Refrigerant hose/line. An A/C evaporator core orifice or an O-ring seal are not considered major components. The suction accumulator/drier is mounted on the A/C accumulator bracket to the RH side of the instrument panel in the engine compartment. The inlet tube of the suction accumulator/drier is attached to the A/C evaporator core outlet tube. The outlet tube of the suction accumulator/drier attaches to the A/C manifold and tube. A desiccant bag located inside the suction accumulator/drier absorbs any moisture in the refrigerant system. After entering the inlet of the suction accumulator/drier, heavier oil-laden and liquid refrigerant contacts an internally mounted dome and drips down onto the bottom of the canister. A small diameter oil bleed hole in the bottom of the vapor return tube allows the accumulated refrigerant and oil mixture to re-enter the compressor suction line at a controlled rate. A fine-meshed screened filter fits tightly around the bottom of the vapor return tube to filter out refrigerant system contaminant particles. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation > Page 10299 Receiver Dryer: Service and Repair Spring Lock Coupling Disconnect Tool Set Spring Lock Coupling Disconnect Tool (5/8 Inch) Spring Lock Coupling Spring Lock Coupling Special Tools REMOVAL CAUTION: Replacement of the suction accumulator/drier is necessary any time a major component of the refrigerant system is replaced. Failure to replace the suction accumulator/drier will expose the refrigerant system to excessive moisture accumulation. The suction accumulator/drier should also be replaced if the suction accumulator/drier is perforated, if the refrigerant system has been opened to the atmosphere for other than a minor repair or there is evidence of moisture in the system (internal corrosion of metal refrigerant lines or refrigerant oil is thick and dark). NOTE: Compressor oil from vehicles equipped with an FS-10 A/C compressor may have a darker color while maintaining a normal oil viscosity. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation > Page 10300 1. Disconnect the battery ground cable. 2. Recover the refrigerant from the system. See: Service and Repair/Refrigerant Recovery 3. Disconnect the A/C cycling pressure switch electrical connector. 4. Disconnect the manifold and tube fitting. 5. Remove the accumulator bracket clamping bolt. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation > Page 10301 6. Fit Spring Lock Coupling Disconnect Tool to the condenser lines so that the spring lock coupling tool can enter the cage opening to release the A/C tube lock coupling spring. 7. Push the tool into the cage opening to release the female fitting from the A/C tube lock coupling spring. 8. Pull the spring lock coupling fittings apart. 9. Remove the suction accumulator/drier. 10. Drain the oil from the removed suction accumulator/drier into a suitable measuring container. It may he necessary to drill one or two 12.7 mm (1/2 inch) holes in the bottom of the old suction accumulator/drier to make sure that all the oil has drained out. INSTALLATION 1. Add refrigerant oil. ^ Use Motorcraft YN-12b Refrigerant Oil F2AZ-19577-AC or equivalent meeting Ford specification WSH-M1C231-B. NOTE: Add the same amount of clean new refrigerant oil that was removed, plus 59 ml (two fluid ounces) to the new suction accumulator/drier. Use only the oil specified for the vehicle being serviced. 2. Transfer the A/C cycling pressure switch to the new suction accumulator/drier. 3. Install new O-rings. NOTE: Lubricate new O-ring seals liberally with clean Motorcraft YN-12b Refrigerant Oil F2AZ-19577-AC or equivalent meeting Ford Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation > Page 10302 specification WSH-M1C231-B. 4. Install the suction accumulator/drier. 5. Install the accumulator bracket clamping bolt. 6. Check for a missing or damaged A/C tube lock coupling spring. A damaged spring can be removed with a small hooked wire. Install a new spring if the old one is damaged or missing. 7. Clean the fittings. 8. On the (A) female spring lock coupling, check the inside of each fitting for scratches, corrosion or debris from deteriorated (B) O-rings. ^ Remove any surface residue from the inside of the coupling by polishing with 400-grit emery cloth (or equivalent). Polish the surface by using a twisting motion so that any scratches made will not cross the O-ring sealing surface. Finish polishing with 600-grit emery cloth or equivalent. Remove all polishing residue from the fitting with a lint free cloth. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation > Page 10303 9. Use the (A) plastic O-ring tool supplied in O-ring kit or equivalent to remove the (B) O-ring seals from the male fitting. NOTE: Do not use metal O-ring tools. They can cause axial scratches across the O-ring grooves, resulting in refrigerant leakage. 10. Install the O-ring seals. Lubricate new O-ring seals. ^ Use Motorcraft Refrigerant Oil YN-12b, F2AZ-19577-AC or equivalent meeting Ford specification WSH-M1C231-B to lubricate seals. NOTE: Use only specified O-ring seals. Use of any O-ring seal other than the one specified may allow the connection to leak intermittently during vehicle operation. 11. Lubricate the male fitting and O-ring seals, and the inside of the female fitting. ^ Use Motorcraft Refrigerant Oil YN-12b, F2AZ-19577-AC or equivalent meeting Ford specification WSH-M1C231-B. 12. Install a plastic indicator ring into cage opening if an indicator ring is to be used. 13. Fit the female fitting to the male fitting and push with a twisting motion until the garter spring snaps over the flared end of the female fitting. NOTE: If a plastic indicator ring is used, it will snap out of the cage opening when the coupling is connected to indicate engagement. 14. If an indicator ring is not used, check the coupling engagement by making sure the garter spring is over the flared end of the fitting. 15. Connect the manifold tube fitting. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation > Page 10304 16. Connect the A/C cycling pressure switch electrical connector. 17. Connect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. 18. Leak test the system. 19. Evacuate and charge the system. See: Service and Repair/Evacuation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation > Page 10305 Receiver Dryer: Tools and Equipment Spring Lock Coupling Disconnect Tool Set Spring Lock Coupling Disconnect Tool (5/8 Inch) Spring Lock Coupling Spring Lock Coupling Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants Technical Service Bulletin # 99-19-6 Date: 990920 A/C - Identification of Non Approved Refrigerants Article No. 99-19-6 09/20/99 ^ AIR CONDITIONING - IDENTIFICATION OF NON-FORD APPROVED REFRIGERANTS ^ AIR CONDITIONING - PURGING AIR FROM SYSTEM FORD: 1985-1986 LTD 1985-1988 EXP 1985-1994 TEMPO 1985-1997 THUNDERBIRD 1985-2000 CROWN VICTORIA, ESCORT, MUSTANG 1986-2000 TAURUS 1988-1993 FESTIVA 1989-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2000 FOCUS 1985-1990 BRONCO II 1985-1996 BRONCO 1985-1997 F-250 HD, F-350 1985-2000 ECONOLINE, F-150, F-250 LD, RANGER 1986-1997 AEROSTAR 1988-1997 F SUPER DUTY 1991-2000 EXPLORER 1995-2000 WINDSTAR 1997-2000 EXPEDITION 1999-2000 SUPER DUTY F SERIES 1985-1991 CL-CLT-9000 SERIES 1985-1999 L SERIES 1985-2000 F & B SERIES 1986-1998 CARGO SERIES 1997-1998 AEROMAX, LOUISVILLE LINCOLN: 1985-1992 MARK VII 1985-2000 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000 LS 1998-2000 NAVIGATOR MERCURY: 1985-1986 MARQUIS 1985-1987 LYNX 1985-1994 TOPAZ 1985-1997 COUGAR 1985-2000 GRAND MARQUIS 1986-2000 SABLE 1987-1989 TRACER 1991-1994 CAPRI 1991-2000 TRACER 1995-2000 MYSTIQUE 1999-2000 COUGAR 1993-2000 VILLAGER 1997-2000 MOUNTAINEER MERKUR: 1985-1989 XR4TI 1988-1989 SCORPIO Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 10310 This TSB article is being republished in its entirety to add model year vehicles ISSUE A number of non-approved/alternate refrigerants have entered the marketplace and are being advertised as "drop-in replacements" for R-12 and R-134a. The use of non-approved refrigerants such as R-22, hydrocarbons, and other refrigerant blends could cause safety, durability, and performance concerns if they are installed in Ford A/C systems. Identification of the type of refrigerant contained in vehicle A/C systems, before servicing, is necessary to prevent dealer service equipment and refrigerant supplies from being contaminated with non-approved refrigerants. ACTION Refrigerant identification must be performed prior to recovering the refrigerant into a recovery machine to prevent cross-contamination of the recovery machine and other A/C systems being serviced with that recovery machine. Refer to the following text. OTHER APPLICABLE ARTICLES: 94-14-3, 95-18-4 SUPERSEDES: 98-12-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1993-2000 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 991906A Test A/C System For 0.3 Hr. Contaminated Refrigerant DEALER CODING CONDITION BASIC PART NO. CODE R-12 49 OASIS CODES: 208000, 208999 A/C Refrigerant Analyzer Function Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 10311 Ford Motor Company has approved the Rotunda Deluxe A/C Refrigerant Analyzer (198-00003) for use on Ford and Lincoln-Mercury vehicles (Figure 1). The analyzer provides the technician with a quick and easy way to identify the type and percentage of refrigerant (R-134a, R-12, R-22, or flammable hydrocarbon). The analyzer can also provide the percentage of air in the A/C system and automatically purge air from the system. The A/C Refrigerant Analyzer is designed to identify vapor gas samples taken directly from automotive air conditioning systems or refrigerant storage cylinders. Refrigerant vapor passes through the multiple sensor Non-Dispersive Infra-Red (NDIR) sensing unit. The microprocessor calculates each refrigerant type and purity percentage which is displayed on the analyzer's Liquid Crystal Display (LCD). The analyzer identifies the purity percentage of R-134a, R-12, R-22, hydrocarbon; and air in the sample. If the purity percentage of the R-134a or R-12 is 98% or greater by weight, a green "PASS" Light Emitting Diode (LED) will light. If refrigerants R-134a or R-12 do not meet 98% purity levels, the red "FAIL" LED will light. Levels of R-22 and flammable hydrocarbons above 2% will light the red "FAIL" light. If a hydrocarbon is detected above 5%, both the "FAIL" light and "HYDROCARBON" light will illuminate and a horn will sound alerting the user of potential hazards. The percent of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or above. The analyzer eliminates the effect of air Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 10312 when determining the refrigerant sample content because air is not considered a contaminant although air can affect A/C system performance. Air will automatically be purged until a pure refrigerant with a less than 2% by weight air measurement is reached. Recovery of Contaminated Refrigerant If contaminated refrigerant is detected, DO NOT recover the refrigerant into your R-134a or R-12 recovery/recycling equipment. Take the following actions: 1. Repeat the test to verify contaminated refrigerant is present. 2. Advise the customer of the contaminated A/C system and any additional cost to repair the system. The customer may wish to return to the service facility which performed the last A/C service. 3. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. This equipment must only be used to recover contaminated refrigerant to prevent the spread to other vehicles. As an alternative, contact an A/C service facility in your area which has the proper equipment for refrigerant recovery. Repairing A Contaminated A/C System Once the contaminated refrigerant is removed from the system it will be necessary to repair the system. Ford recommends that you do the following to be sure a quality repair is made: 1. Determine the cause of the failure. 2. Determine which parts will need to be replaced. 3. Flush the heat exchangers to remove any oil that may be degraded due to the contaminated refrigerant. 4. Install a new suction/accumulator. 5. Properly oil match the system to verify that the correct amount of clean refrigerant oil is present in the system. 6. Evacuate the system for 45 minutes. 7. Recharge the system, verify proper operation, and leak test. Disposal of Contaminated Refrigerant Disposal of contaminated refrigerant is a new process to the automotive industry Listed below are companies that will assist with disposal of contaminated refrigerant. Ford Motor Company has not evaluated the processes of the listed refrigerant disposal companies and is not endorsing or promoting their companies Business transactions are between the dealership and disposal companies. Disposal costs will vary between $3.00 and $5.00 per pound, plus the cost of round trip cylinder shipping. ^ Omega Refrigerant Reclamation ^ 5263 North Fourth St. ^ Irwindale, CA 91706 ^ (310) 698-0991 FAX: (310) 696-7908 ^ Full Cycle Global ^ 2966 Wireton ^ Blue Island, IL 60406 ^ (708) 388-8551 FAX: (708) 399-6550 ^ U.S. Refrigerant Reclaim, Inc. ^ 12420 North Green River Road ^ Evansville, IN 47711 ^ (800) 207-5931 FAX: (812) 867-1463 ^ Full Cycle Global ^ 343 South Airline Highway Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 10313 ^ Gonzales, LA 70737 ^ (504) 644-5333 FAX: (504) 644-1609 ^ CFC Reclamation ^ 1321 Swift North ^ Kansas City, MO 64116 ^ (816) 471-2511 ^ Full Cycle Global ^ 550 James St. ^ Lakewood, NJ 08701 ^ (908) 370-3400 FAX: (908) 370-3088 ^ National Refrigerants, Inc. ^ 11401 Roosevelt Blvd. ^ Philadelphia, PA 19154 ^ (215) 698-6620 FAX: (215) 602-8205 ^ Gartech Refrigerant Reclamation ^ 2002 Platinum ^ Garland, TX 75042 ^ (214) 272-4070 FAX: (214) 272-6548 ^ Refrigerant Reclaim Services ^ 121 S. Norwood Dr. ^ Hurst, TX 76053-7807 ^ (817) 282-0022 FAX: (800) 831-6182 ^ Full Cycle Global ^ 2055 Silber, Suite 109 ^ Houston, TX 77055 ^ (713) 681-7370 FAX: (713) 681-9947 ^ Refrigerant Reclaim, Inc. ^ 122 Old Stage Coach Road ^ Dumfries, VA 22026 ^ (800) 238-5902 FAX: (703) 441-0393 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 10314 Technical Service Bulletin # 98-12-5 Date: 980622 A/C - Filtering Refrigerant After Compressor Replacement Article No. 98-12-5 06/22/98 AIR CONDITIONING - FILTERING REFRIGERANT AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86 CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII 1995-98-MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150, F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98 EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to revise the Service Procedure and to update the model years. ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the refrigerant system cleaned to remove any debris or contaminants that may be present to prevent damage to the replacement compressor. ACTION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 10315 Install a Service Filter Kit in the refrigerant system prior to installing the replacement compressor. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-15-5 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-99 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models And Major Component Warranty Coverage For All Other Lincoins OPERATION DESCRIPTION TIME 981205A Kit Installation 1.2 Hrs. 981205B Extra Time For Refrigerant 0.4 Hr. (R-12) Recovery DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208999 Service Procedure THIS PROCEDURE IS OPTIONAL IF THE SYSTEM IS FLUSHED USING THE ROTUNDA A/C FLUSHER. CAUTION THIS FILTERING PROCEDURE MAY BE USED FOR EITHER R-12 OR R-134a REFRIGERANT SYSTEMS. BECAUSE THE TWO (2) SYSTEMS USE DIFFERENT REFRIGERANT OILS AND BECAUSE THE COMPRESSOR COULD BE DAMAGED IF THE WRONG OIL IS USED, SYSTEM IDENTIFICATION IS VERY IMPORTANT. BE SURE SYSTEM IS CORRECTLY IDENTIFIED BEFORE STARTING THE FILTERING PROCEDURE. Each Service Filter Kit includes the following items: ^ One (1) Pancake Filter (to be installed in the liquid line between the condenser and the orifice tube) ^ One (1) Instruction Sheet NOTE ON 1993-94 RANGER/EXPLORER VEHICLES, TECHNICIANS MAY EXPERIENCE DIFFICULTY WHEN CONNECTING THE PANCAKE FILTER HOSE FITTINGS TO THE EVAPORATOR INLET WITH THE ORIFICE TUBE INSTALLED. REMOVE THE OFFICE TUBE AND RUN THE SYSTEM FOR 1 HOUR AS DESCRIBED IN THE FILTERING PROCEDURE. REINSTALL THE ORIFICE TUBE AFTER FILTERING IS COMPLETE. CAUTION FOLLOW ALL REFRIGERANT SYSTEM SAFETY AND SERVICE PRECAUTIONS OUTLINED IN THE APPROPRIATE SERVICE OR WORKSHOP MANUAL. 1. Before removing any refrigerant system components, recover the refrigerant from the system following the recycling methods outlined In the appropriate Service/Workshop Manual. 2. Remove the suction accumulator/drier assembly and drain the oil into a calibrated container. 3. Install a new suction accumulator/drier and add new refrigerant oil to replace the old oil. The quantity of the new oil to be added is the amount to match that drained from the old accumulator plus 60 mL (2 oz). Refer to the Dealer Master Parts Catalog for the correct suction accumulator/drier part number. CAUTION REMEMBER TO USE MOTORCRAFT YN-9-A REFRIGERANT COMPRESSOR OIL WITH R-12 SYSTEMS AND MOTORCRAFT YN-12-C REFRIGERANT COMPRESSOR OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. 4. Install a new orifice tube. Refer to the Dealer Master Parts Catalog for the correct orifice tube part number. If the orifice tube in the vehicle is located in the liquid line between the condenser and the evaporator, replace the liquid line assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 10316 5. Install pancake filter in the liquid line between the condenser and the orifice tube, Figure 1. a. Be sure orifice inlet is toward the condenser. b. Connections can be made using Test Adapter Set D93L-19703-B, or equivalent, and flexible refrigerant hose of 2500 psi burst rating. Individual fittings are also available. 6. Remove the old compressor following Service/Workshop Manual procedures. Drain the oil into a calibrated container. 7. Drain the oil from the replacement compressor into a clean calibrated container. NOTE: IT WILL BE NECESSARY TO TRANSFER THE MAGNET CLUTCH FROM THE OLD COMPRESSOR TO THE REPLACEMENT COMPRESSOR. FOLLOW SERVICE/WORKSHOP MANUAL PROCEDURES. 8. A new FX-15 service compressor contains 207 mL (7 oz.) of R-12 refrigerant oil. A new FS-10 service compressor does not contain any oil and can be used with an R-12 or an R-134a system. CAUTION REMEMBER TO USE YN-9-A (MINERAL) OIL WITH R-12 SYSTEMS AND YN-12-C (PAG) OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. ^ If the amount of oil drained from the removed compressor is between 90 and 148 mL (3-5 oz), pour the same amount of clean refrigerant oil into the new compressor. ^ If the amount of oil drained from the old compressor is greater than 90 mL (3 oz), pour 90 mL (3 oz) of clean refrigerant oil into the new compressor. 9. Install the new compressor following Service/Workshop Manual procedures. Make sure all mounting bolts are tightened properly. Check the tension of the compressor drive belt. Adjust if necessary. 10. Evacuate, charge and leak test the system, following Service/Workshop Manual procedures. 11. Check all refrigerant system hoses, lines and the position of the newly-installed filters to make sure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments. 12. Set the A/C control on Max A/C, high blower and temperature control at full cold. a. Start engine and let idle briefly. b. Be sure A/C system is operating properly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 10317 13. Gradually bring the engine up to 1200 rpm by running it at lower rpms for short periods (first at 800 rpm, then at 1000 rpm). Set the engine at 1200 rpm and run it for an hour with the A/C system operating. 14. Stop the engine. NOTE: IT WILL BE NECESSARY TO RECOVER THE SYSTEM REFRIGERANT CHARGE BEFORE PROCEEDING. 15. Allow the engine to cool sufficiently to remove the fittings, flexible hoses and pancake filter from the liquid line. 16. Discard the filter. It can be used one (1) tie only. 17. Reconnect the liquid line back into the system. 18. Evacuate, charge and leak test the system. Make any necessary adjustments. 19. Check the operation of the system in all models. PART NUMBER PART NAME F8VZ-19E773-AA Filter Kit F73Z-19577-AA Refrigerant Oil - Motorcraft YN-9-A (For R-12 Refrigerant Systems Only) F7AZ-19589-DA Refrigerant Oil - Motorcraft YN-12-C (PAG-Type Oil For R-134a Refrigerant Systems Only) NOTE THE TOTAL REPAIR TIME IS FOR INSTALLING SERVICE FILTER KIT PER INSTRUCTIONS THIS INCLUDES INSTALLATION OF AND DISCARD OF FILTER. REFER TO SERVICE LABOR TIME STANDARDS MANUALS IF ADDITIONAL LABOR OPERATIONS ARE REQUIRED. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 10318 Refrigerant: Technical Service Bulletins A/C - R134a Tracer Dye and Three O Ring Spring Couplers Article No. 97-3-5 02/03/97 AIR CONDITIONING - R-134A TRACER DYE INSTALLED IN A/C SYSTEM AND THREE 0-RING SPRING LOCK COUPLERS - SERVICE TIP FORD: 1996-97 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1996-97 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VIII, MYSTIQUE, SABLE, TOWN CAR, TRACER LIGHT TRUCK: 1996 BRONCO 1996-97 AEROSTAR, ECONOLINE, EXPLORER, F-150-350 SERIES, RANGER, WINDSTAR 1997 EXPEDITION, MOUNTAINEER This TSB article is being republished in its entirety to update the text. ISSUE: Ford Motor Company now produces new vehicles with R-134a fluorescent tracer dye incorporated into the A/C system and spring lock couplings which contain three (3) O-rings. ACTION: Leak checking can be performed with the use of a Rotunda UV Lamp (112-R0021) and is an acceptable alternative to using an electronic leak detector. Ford Motor Company has begun implementation of spring lock couplings with three (3) O-rings which provide an improved seal. Field and laboratory tests have shown a 40% improvement in sealing capability and durable life. Through field and fleet testing and analysis, it is apparent that lubricating oil used in vehicle assembly processes is easily misdiagnosed as a refrigerant leak. The presence of oil at connections is not necessarily an indication of a leaking connection. If oil at a fitting is due to a leak, fluorescent tracer dye will be present at the location. Any oil escaping from the A/C hoses will contain dye. When checking for leaks, be sure to scan all components, fittings and lines of the A/C system with the UV lamp. The exact location of the leak or leaks can be pinpointed by the bright yellow-green glow of the tracer dye. Since more than one leak may exist in the system, always inspect each component. The best leak detection results will be achieved in conditions of low ambient light. In areas that cannot be reached by the UV lamp: (1) use a technician's mirror or (2) use a non-fluorescent shop towel, wipe the suspected area, and then check the towel with the UV lamp for traces of the dye. After the leak is repaired, the traces of dye can be removed from the previously leaking areas by using any general purpose oil solvent. Verify the repair by operating the A/C system for a short while and reinspecting the system with the UV lamp. NOTE: BEGINNING WITH VEHICLES PRODUCED IN MAY 1996, THE TRACER DYE'S FLUORESCENT LIFESPAN IS THE LIFE OF THE VEHICLE. VEHICLES PRODUCED BEFORE MAY 1996 CONTAIN A TRACER DYE WITH A LIFESPAN OF ROUGHLY 500 HOURS OF NC SYSTEM USE, AFTER WHICH TIME ANOTHER INFUSION OF DYE WOULD BE REQUIRED. REFER TO TSB 94-26-6 AND 95-21-4 IF ADDITIONAL TRACER DYE OR INFORMATION IS REQUIRED. OTHER APPLICABLE ARTICLES: 94-23-10, 94-26-6, 95-21-4, 96-15-6 SUPERSEDES: 95-21-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200, 208999 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Capacity Capacity With Auxiliary A/C Without Auxiliary A/C Refrigerant Charge 62 oz. 37 oz. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 10321 Refrigerant: Fluid Type Specifications Refrigerant Type .................................................................................................................................. ...................................................................... R-134a Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement Technical Service Bulletin # 98-12-5 Date: 980622 A/C - Filtering Refrigerant After Compressor Replacement Article No. 98-12-5 06/22/98 AIR CONDITIONING - FILTERING REFRIGERANT AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86 CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII 1995-98-MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150, F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98 EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to revise the Service Procedure and to update the model years. ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the refrigerant system cleaned to remove any debris or contaminants that may be present to prevent damage to the replacement compressor. ACTION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 10326 Install a Service Filter Kit in the refrigerant system prior to installing the replacement compressor. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-15-5 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-99 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models And Major Component Warranty Coverage For All Other Lincoins OPERATION DESCRIPTION TIME 981205A Kit Installation 1.2 Hrs. 981205B Extra Time For Refrigerant 0.4 Hr. (R-12) Recovery DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208999 Service Procedure THIS PROCEDURE IS OPTIONAL IF THE SYSTEM IS FLUSHED USING THE ROTUNDA A/C FLUSHER. CAUTION THIS FILTERING PROCEDURE MAY BE USED FOR EITHER R-12 OR R-134a REFRIGERANT SYSTEMS. BECAUSE THE TWO (2) SYSTEMS USE DIFFERENT REFRIGERANT OILS AND BECAUSE THE COMPRESSOR COULD BE DAMAGED IF THE WRONG OIL IS USED, SYSTEM IDENTIFICATION IS VERY IMPORTANT. BE SURE SYSTEM IS CORRECTLY IDENTIFIED BEFORE STARTING THE FILTERING PROCEDURE. Each Service Filter Kit includes the following items: ^ One (1) Pancake Filter (to be installed in the liquid line between the condenser and the orifice tube) ^ One (1) Instruction Sheet NOTE ON 1993-94 RANGER/EXPLORER VEHICLES, TECHNICIANS MAY EXPERIENCE DIFFICULTY WHEN CONNECTING THE PANCAKE FILTER HOSE FITTINGS TO THE EVAPORATOR INLET WITH THE ORIFICE TUBE INSTALLED. REMOVE THE OFFICE TUBE AND RUN THE SYSTEM FOR 1 HOUR AS DESCRIBED IN THE FILTERING PROCEDURE. REINSTALL THE ORIFICE TUBE AFTER FILTERING IS COMPLETE. CAUTION FOLLOW ALL REFRIGERANT SYSTEM SAFETY AND SERVICE PRECAUTIONS OUTLINED IN THE APPROPRIATE SERVICE OR WORKSHOP MANUAL. 1. Before removing any refrigerant system components, recover the refrigerant from the system following the recycling methods outlined In the appropriate Service/Workshop Manual. 2. Remove the suction accumulator/drier assembly and drain the oil into a calibrated container. 3. Install a new suction accumulator/drier and add new refrigerant oil to replace the old oil. The quantity of the new oil to be added is the amount to match that drained from the old accumulator plus 60 mL (2 oz). Refer to the Dealer Master Parts Catalog for the correct suction accumulator/drier part number. CAUTION REMEMBER TO USE MOTORCRAFT YN-9-A REFRIGERANT COMPRESSOR OIL WITH R-12 SYSTEMS AND MOTORCRAFT YN-12-C REFRIGERANT COMPRESSOR OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. 4. Install a new orifice tube. Refer to the Dealer Master Parts Catalog for the correct orifice tube part number. If the orifice tube in the vehicle is located in the liquid line between the condenser and the evaporator, replace the liquid line assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 10327 5. Install pancake filter in the liquid line between the condenser and the orifice tube, Figure 1. a. Be sure orifice inlet is toward the condenser. b. Connections can be made using Test Adapter Set D93L-19703-B, or equivalent, and flexible refrigerant hose of 2500 psi burst rating. Individual fittings are also available. 6. Remove the old compressor following Service/Workshop Manual procedures. Drain the oil into a calibrated container. 7. Drain the oil from the replacement compressor into a clean calibrated container. NOTE: IT WILL BE NECESSARY TO TRANSFER THE MAGNET CLUTCH FROM THE OLD COMPRESSOR TO THE REPLACEMENT COMPRESSOR. FOLLOW SERVICE/WORKSHOP MANUAL PROCEDURES. 8. A new FX-15 service compressor contains 207 mL (7 oz.) of R-12 refrigerant oil. A new FS-10 service compressor does not contain any oil and can be used with an R-12 or an R-134a system. CAUTION REMEMBER TO USE YN-9-A (MINERAL) OIL WITH R-12 SYSTEMS AND YN-12-C (PAG) OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. ^ If the amount of oil drained from the removed compressor is between 90 and 148 mL (3-5 oz), pour the same amount of clean refrigerant oil into the new compressor. ^ If the amount of oil drained from the old compressor is greater than 90 mL (3 oz), pour 90 mL (3 oz) of clean refrigerant oil into the new compressor. 9. Install the new compressor following Service/Workshop Manual procedures. Make sure all mounting bolts are tightened properly. Check the tension of the compressor drive belt. Adjust if necessary. 10. Evacuate, charge and leak test the system, following Service/Workshop Manual procedures. 11. Check all refrigerant system hoses, lines and the position of the newly-installed filters to make sure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments. 12. Set the A/C control on Max A/C, high blower and temperature control at full cold. a. Start engine and let idle briefly. b. Be sure A/C system is operating properly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 10328 13. Gradually bring the engine up to 1200 rpm by running it at lower rpms for short periods (first at 800 rpm, then at 1000 rpm). Set the engine at 1200 rpm and run it for an hour with the A/C system operating. 14. Stop the engine. NOTE: IT WILL BE NECESSARY TO RECOVER THE SYSTEM REFRIGERANT CHARGE BEFORE PROCEEDING. 15. Allow the engine to cool sufficiently to remove the fittings, flexible hoses and pancake filter from the liquid line. 16. Discard the filter. It can be used one (1) tie only. 17. Reconnect the liquid line back into the system. 18. Evacuate, charge and leak test the system. Make any necessary adjustments. 19. Check the operation of the system in all models. PART NUMBER PART NAME F8VZ-19E773-AA Filter Kit F73Z-19577-AA Refrigerant Oil - Motorcraft YN-9-A (For R-12 Refrigerant Systems Only) F7AZ-19589-DA Refrigerant Oil - Motorcraft YN-12-C (PAG-Type Oil For R-134a Refrigerant Systems Only) NOTE THE TOTAL REPAIR TIME IS FOR INSTALLING SERVICE FILTER KIT PER INSTRUCTIONS THIS INCLUDES INSTALLATION OF AND DISCARD OF FILTER. REFER TO SERVICE LABOR TIME STANDARDS MANUALS IF ADDITIONAL LABOR OPERATIONS ARE REQUIRED. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > A/C - Refrigerant Oil Refill Capacity Refrigerant Oil: Technical Service Bulletins A/C - Refrigerant Oil Refill Capacity Article No. 97-15-5 07/21/97 AIR CONDITIONING - OIL REFILL CAPACITY CHART - SERVICE TIP FORD: 1994 TEMPO 1994-97 ASPIRE, PROBE, THUNDERBIRD 1994-98 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1995-98 CONTOUR LINCOLN-MERCURY: 1994 CAPRI, TOPAZ 1994-97 COUGAR 1994-98 CONTINENTAL, GRAND MARQUIS, MARK VIII, SABLE, TOWN CAR, TRACER 1995-98 MYSTIQUE LIGHT TRUCK: 1994-96 BRONCO 1994-97 AEROSTAR 1994-98 ECONOLINE, EXPLORER, F-150-350 SERIES, RANGER, VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: This TSB article will provide an easy and quick reference chart for determining the correct amount of refrigerant oil to use when servicing an A/C system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > A/C - Refrigerant Oil Refill Capacity > Page 10333 ACTION: Refer to Figure 1 to determine how much refrigerant oil is needed to service an A/C system. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200, 208999 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications REFRIGERANT OIL ADDITION During A/C Compressor Replacement A new FS-10 service replacement A/C compressor contains no refrigerant oil. a. If the amount of oil drained from the removed A/C compressor is between 85 and 142 ml (3 oz to 5 oz), pour the same amount plus one ounce of clean oil into the new A/C compressor. b. If the amount of oil drained from the old A/C compressor is greater than 142 ml (5 oz), pour only 142 ml (5 oz) of clean refrigerant oil into the new A/C compressor. c. If the amount of refrigerant oil drained from the old A/C compressor is less than 85 ml (3 oz), pour 85 ml (3 oz) of clean refrigerant oil into the new compressor. During Replacement of A/C Refrigerant Components When replacing components of the air-conditioning refrigerant system, add oil to the replacement components. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 10336 Refrigerant Oil: Fluid Type Specifications PAG Compressor Oil (R-134a System) .................................................................................................................................................... WSH-M1C231-B Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 10337 Refrigerant Oil: Service and Repair DURING A/C COMPRESSOR REPLACEMENT 1. A new FS-10 service replacement A/C compressor contains no refrigerant oil. If the amount of oil drained from the removed A/C compressor is between 85 and 142 ml (3 to 5 oz), pour the same amount plus one ounce of clean oil into the new A/C compressor. If the amount of oil drained from the old A/C compressor is greater than 142 ml (5 oz), pour only 142 ml (5 oz) of clean refrigerant oil into the new A/C compressor. If the amount of refrigerant oil drained from the old A/C compressor is less than 85 ml (3 oz), pour 85 ml (3 oz) of clean refrigerant oil into the new compressor. ^ When replacing components of the air-conditioning refrigerant system, add oil to the replacement components. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications Refrigerant Pressure Sensor / Switch: Specifications Pressure Cut-Off Switch ............................................................................................................................................................ 6.8-1.3 N.m (61-121 Lb/In) A/C Cycling Switch ................................................................................... .................................................................................. 1.4-5.4 N.m (12-48 Lb/In) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Cutoff Switch Typical Air Conditioning Pressure Sensor An A/C pressure cut off switch is used on all vehicles to interrupt operation of the A/C compressor in the event of high system discharge pressures. The switch is located in the discharge line between the A/C compressor and the A/C condenser core. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch > Page 10343 Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Switch The A/C cycling switch is mounted on a Schrader-type fitting on the top of the suction accumulator/drier. A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the Schrader valve stem. This allows the suction pressure inside the suction accumulator/drier to control the operation of the A/C cycling switch. The electrical switch contacts open when the suction pressure drops to 151-165 kPa (22.0-24.0 psi). The contacts close when the suction pressure rises to 276-324 kPa (40-47 psi). This is due to the pressure/temperature relationship of the refrigerant and the requirement of the system pressure to reach 276-324 kPa (40-47 psi) to close the A/C cycling pressure switch contacts. These contacts control the electrical circuit to the A/C clutch field coil. When the A/C cycling pressure switch contacts close, voltage is supplied to energize the A/C clutch for operation of the A/C compressor. When the A/C cycling pressure switch contacts open, the A/C clutch is de-energized and operation of the A/C compressor stops. The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin surface temperature will be maintained slightly above freezing. This prevents icing of the A/C evaporator core and blockage of airflow. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch Refrigerant Pressure Sensor / Switch: Service and Repair A/C Cycling Switch REMOVAL 1. Disconnect the A/C cycling pressure switch electrical connector. 2. Remove the A/C cycling switch from the top of the suction accumulator/drier. INSTALLATION 1. Lubricate the new O-ring seal. ^ Use Motorcraft YN-12b Refrigerant Oil F2AZ-19577-AC or equivalent meeting Ford specification WSH-M1C231-B. 2. Install the A/C cycling switch onto the top of the suction accumulator/drier. 3. Reconnect the A/C cycling pressure switch wiring connector. 4. Check for refrigerant leaks. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch > Page 10346 Refrigerant Pressure Sensor / Switch: Service and Repair A/C Pressure Cut-Off Switch REMOVAL 1. Disconnect the A/C pressure cut-off switch electrical connector or discharge line. 2. Remove the A/C pressure cut-off switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 10351 Power/Flasher Relay Block The Blower Relay is located in the blower/flasher relay block. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 10352 Blower Motor Relay: Testing and Inspection Digital Multimeter Special Tools RELAY COMPONENT TEST Testing of an ISO relay can be accomplished through the use of three No. 10 (or larger gauge) jumper wires and a 73 Digital Multimeter. Remove (unplug) the relay to be tested from the engine compartment fuse junction panel, I/P fuse junction panel or individual connector. Mini ISO Relay Use 73 Digital Multimeter to check for the continuity between terminal 85 and all other terminals. If resistance is 5 ohms or less between terminal 85 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay terminals 86 and 30 directly to the positive battery terminal. With the multimeter set in the volts position, check for voltage at terminal 87A. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 85 and ground the jumper wire to a known good ground. Check for voltage at terminal 87. If battery voltage is not indicated, replace the relay. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 10353 Blower Motor Relay: Tools and Equipment Digital Multimeter Special Tools Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations As shown in the wiring diagrams, these vehicles do not use a compressor cut-off (also called a wide open throttle or WOT) relay. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Door Position Sensor / Switch, HVAC > Component Information > Diagrams > Air Door Position Sensor / Switch, HVAC Air Door Position Sensor / Switch: Diagrams Air Door Position Sensor / Switch, HVAC Front Mode Potentiometer Rear Mode Potentiometer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Door Position Sensor / Switch, HVAC > Component Information > Diagrams > Air Door Position Sensor / Switch, HVAC > Page 10362 Air Door Position Sensor / Switch: Diagrams Blend Door Position Sensor Front Blend Potentiometer Rear Blend Potentiometer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Blower Switch Blower Motor Switch: Diagrams Blower Switch Front Blower Motor Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Blower Switch > Page 10367 Rear Blower Motor Switch Rear Integrated Control Panel (Rear Blower Switch) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Blower Switch > Page 10368 Blower Motor Switch: Diagrams Blower Switch Illumination Front Blower Switch Illumination Rear Blower Switch Illumination Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Testing and Inspection > Blower Switch Blower Motor Switch: Testing and Inspection Blower Switch Blower Motor Switch - Component Testing Procedure Blower Motor Switch - Terminal Locations Blower Motor Switch - Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Testing and Inspection > Blower Switch > Page 10371 Blower Motor Switch: Testing and Inspection Front Blower Switch Front Blower Motor Switch - Component Testing Procedure Front Blower Motor Switch - Terminal Locations Front Blower Motor Switch - Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Testing and Inspection > Blower Switch > Page 10372 Blower Motor Switch: Testing and Inspection Rear Auxiliary Rear Blower Motor Switch - Component Testing Procedure Rear Blower Motor Switch - Terminal Locations Rear Blower Motor Switch - Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications Refrigerant Pressure Sensor / Switch: Specifications Pressure Cut-Off Switch ............................................................................................................................................................ 6.8-1.3 N.m (61-121 Lb/In) A/C Cycling Switch ................................................................................... .................................................................................. 1.4-5.4 N.m (12-48 Lb/In) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Cutoff Switch Typical Air Conditioning Pressure Sensor An A/C pressure cut off switch is used on all vehicles to interrupt operation of the A/C compressor in the event of high system discharge pressures. The switch is located in the discharge line between the A/C compressor and the A/C condenser core. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch > Page 10378 Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Switch The A/C cycling switch is mounted on a Schrader-type fitting on the top of the suction accumulator/drier. A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the Schrader valve stem. This allows the suction pressure inside the suction accumulator/drier to control the operation of the A/C cycling switch. The electrical switch contacts open when the suction pressure drops to 151-165 kPa (22.0-24.0 psi). The contacts close when the suction pressure rises to 276-324 kPa (40-47 psi). This is due to the pressure/temperature relationship of the refrigerant and the requirement of the system pressure to reach 276-324 kPa (40-47 psi) to close the A/C cycling pressure switch contacts. These contacts control the electrical circuit to the A/C clutch field coil. When the A/C cycling pressure switch contacts close, voltage is supplied to energize the A/C clutch for operation of the A/C compressor. When the A/C cycling pressure switch contacts open, the A/C clutch is de-energized and operation of the A/C compressor stops. The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin surface temperature will be maintained slightly above freezing. This prevents icing of the A/C evaporator core and blockage of airflow. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch Refrigerant Pressure Sensor / Switch: Service and Repair A/C Cycling Switch REMOVAL 1. Disconnect the A/C cycling pressure switch electrical connector. 2. Remove the A/C cycling switch from the top of the suction accumulator/drier. INSTALLATION 1. Lubricate the new O-ring seal. ^ Use Motorcraft YN-12b Refrigerant Oil F2AZ-19577-AC or equivalent meeting Ford specification WSH-M1C231-B. 2. Install the A/C cycling switch onto the top of the suction accumulator/drier. 3. Reconnect the A/C cycling pressure switch wiring connector. 4. Check for refrigerant leaks. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch > Page 10381 Refrigerant Pressure Sensor / Switch: Service and Repair A/C Pressure Cut-Off Switch REMOVAL 1. Disconnect the A/C pressure cut-off switch electrical connector or discharge line. 2. Remove the A/C pressure cut-off switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description and Operation Service Port HVAC: Description and Operation NOTE: R-134a low-side quick connect and R-134a high-side quick connect are required to connect to both the high and low-side ports. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Service and Repair Vacuum Reservoir HVAC: Service and Repair REMOVAL 1. Remove the battery and battery tray bracket. 2. Disconnect the A/C vacuum tank hose for the A/C vacuum reservoir tank and bracket. 3. Remove the screw and the A/C vacuum reservoir tank and bracket. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When positioning the A/C vacuum reservoir tank, make sure that the bottom locator and two top tabs align with the battery tray. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Wiring Harness HVAC > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness HVAC: > 98-23-9 > Nov > 98 > A/C - No/Intermittent Auxiliary A/C Mode/Blower Control Wiring Harness HVAC: Customer Interest A/C - No/Intermittent Auxiliary A/C Mode/Blower Control Article No. 98-23-9 11/23/98 AIR CONDITIONING - NO OR INTERMITTENT AUXILIARY A/C MODE BLOWER CONTROL VEHICLES BUILT THROUGH 9/8/98 LIGHT TRUCK: 1997-98 EXPEDITION 1998 NAVIGATOR ISSUE There may be no or intermittent auxiliary A/C mode/blower control on some vehicles. This may be caused by the -14335- wire harness being cut on the rail edge in the headliner. ACTION Repair harness and install 9 mm (3/8") convolute to protect harness. The convolute should protect the wire harness from being cut on the rail edge. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify concern. 2. Gain access to the -14335- wire harness by removing the left side rear passenger rail edge moulding and assist handle and lowering the headliner. 3. Repair wire harness. 4. Wrap harness with a 12.7cm (5") long piece of 9 mm (27/64") Convolute Wire Shield (D4SZ-14A099-F 25-Ft Bulk). 5. Reinstall rail edge moulding. 6. Verify repair. PART NUMBER PART NAME D4SZ-14A099-F Wire Shield - 27/64" (25-Ft Bulk - Only 5" Is Required) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982309A Repair Wire Harness 0.6 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 14335 B4 OASIS CODES: 203000, 208000, 208100, 208200, 208300, 208999 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Heating and Air Conditioning > Wiring Harness HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness HVAC: > 98-23-9 > Nov > 98 > A/C - No/Intermittent Auxiliary A/C Mode/Blower Control Wiring Harness HVAC: All Technical Service Bulletins A/C - No/Intermittent Auxiliary A/C Mode/Blower Control Article No. 98-23-9 11/23/98 AIR CONDITIONING - NO OR INTERMITTENT AUXILIARY A/C MODE BLOWER CONTROL VEHICLES BUILT THROUGH 9/8/98 LIGHT TRUCK: 1997-98 EXPEDITION 1998 NAVIGATOR ISSUE There may be no or intermittent auxiliary A/C mode/blower control on some vehicles. This may be caused by the -14335- wire harness being cut on the rail edge in the headliner. ACTION Repair harness and install 9 mm (3/8") convolute to protect harness. The convolute should protect the wire harness from being cut on the rail edge. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify concern. 2. Gain access to the -14335- wire harness by removing the left side rear passenger rail edge moulding and assist handle and lowering the headliner. 3. Repair wire harness. 4. Wrap harness with a 12.7cm (5") long piece of 9 mm (27/64") Convolute Wire Shield (D4SZ-14A099-F 25-Ft Bulk). 5. Reinstall rail edge moulding. 6. Verify repair. PART NUMBER PART NAME D4SZ-14A099-F Wire Shield - 27/64" (25-Ft Bulk - Only 5" Is Required) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982309A Repair Wire Harness 0.6 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 14335 B4 OASIS CODES: 203000, 208000, 208100, 208200, 208300, 208999 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming Deactivation Procedure 1. Disconnect positive battery cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Wait one minute. This is the time required for backup power supply in air bag diagnostic monitor to deplete its stored energy. 3. Remove two back cover plugs and remove screw and washer assemblies retaining driver side air bag module to steering wheel. Disconnect horn electrical connector. Disconnect driver air bag sliding contact electrical connector. Remove driver side air bag module from vehicle. WARNING: Place air bag module on bench with trim cover facing up. 4. Connect Rotunda Air Bag Simulator 105-R0011 or equivalent to vehicle harness at top of steering column. 5. Remove passenger side air bag module. Install Rotunda Air Bag Simulator 105-00012 or equivalent on vehicle harness connector in place of passenger side air bag module. 6. Reconnect positive battery cable. Reactivation Procedure 1. Disconnect positive battery cable. WARNING: The air bag simulator must be removed and the air bag reconnected when the system is reactivated. 2. Wait one minute for backup power supply in air bag diagnostic monitor to deplete stored energy. 3. Remove air bag simulator from vehicle harness connector at top of steering column. 4. Reconnect driver side air bag module. 5. Position driver side air bag module on steering wheel and secure with two screw and washer assemblies (8 mm). Tighten screw and washer assemblies to 10-13 Nm (89-115 lb in). Install two back cover plugs. 6. Remove air bag simulator from vehicle harness connector on passenger side. Reconnect and install passenger side air bag module. 7. Reconnect positive battery cable. 8. Prove out system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 10407 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The check list below should be completed following diagnosis or service of any air bag system concern: 1. Are both air bag crash sensors connected and mounted to the vehicle? 2. Is 3-way connector at base of steering column connected? 3. Are the air bags or air bag simulators connected? 4. Is air bag diagnostic monitor connected? 5. Is vehicle battery connected? Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Specifications Air Bag: Specifications TORQUE SPECIFICATIONS Driver Side Air Bag Module Screws .......................................................................................................................................... 10-13 Nm (89-115 lb in) Passenger Side Air Bag Module Screws .................................................................................................................................. 7.6-10.4 Nm (7.6-92 lb in) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Specifications > Page 10411 Air Bag: Service Precautions WARNING: - Always wear safety glasses when repairing an air bag vehicle and when handling an air bag. - Carry a live air bag with the bag and trim cover pointed away from your body. an accidental deployment will then deploy with a minimal chance of injury. - Place a live air bag on a bench or other surface with the trim cover up. - After deployment, the air bag surface may contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. wash your hands with soap and water afterwards. - Repair is made by replacement only. If a part is replaced and the new part does not correct the condition, install the original part and perform the diagnostic procedure again. - Never probe the connectors on the air bags. doing so may result in air bag deployment, which could result in personal injury. - Air bag modules with discolored or damaged covers or deployment doors must be replaced, not repainted. - To avoid accidental deployment and possible injury, the backup power supply must be depleted before repairing or replacing any air bag system components. To deplete the backup power supply energy, disconnect the battery to starter relay cable and wait one minute. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Driver Side Air Bag Module Air Bag: Description and Operation Driver Side Air Bag Module NOTE: The driver side air bag module is serviced as a complete assembly. DESCRIPTION The driver side air bag module is mounted in the center of the steering wheel and consists of the following components: Inflator - When the sensors close, signaling a crash, electrical current flows to the air bag inflator. - Inside the inflator, an igniter converts the current into thermal energy, causing ignition of the inflator gas generant. - This ignition reaction combusts the sodium azide/copper oxide gas generant in the inflator, producing nitrogen gas, which inflates the air bag. NOTE: The inflator assembly is not a serviceable item. Air Bag The air bag is constructed of neoprene coated nylon. It is 711 mm (28 inches) in diameter and fills completely in approximately 40 milliseconds. NOTE: The air bag is not a serviceable item. Mounting Plate and Retainer Ring The mounting plate and retainer ring attach and seal the air bag to the inflator. The mounting bracket and housing are also used to attach the trim cover and to mount the entire driver side air bag module to the steering wheel. NOTE: The mounting plate and retainer ring are not serviceable items. Steering Wheel Trim Cover The cover is an injection-moulded plastic component which encases the driver side air bag module. When the air bag is activated, tear seams moulded into the steering wheel trim cover separate to allow inflation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Driver Side Air Bag Module > Page 10414 NOTE: The steering wheel trim cover is not a serviceable item. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Driver Side Air Bag Module > Page 10415 Air Bag: Description and Operation Passenger Side Air Bag Module NOTE: The passenger side air bag module is serviced as a complete assembly. DESCRIPTION The passenger side air bag module is mounted in the RH position of the instrument panel above the glove compartment and consists of the following components: Inflator - As with the driver side air bag module, an igniter inside the inflator converts electrical energy to thermal energy, causing ignition of the gas generant. - The ignition reaction causes combustion of the sodium azide/iron oxide gas generant producing nitrogen to fill the bag. - Since the passenger side air bag is much larger than the driver air bag, it contains more gas generant in a different inflator configuration to produce more nitrogen gas. NOTE: The passenger side air bag inflator is not a serviceable item. Air Bag The passenger side air bag is constructed of ripstop nylon and fills to a volume of approximately 0.142 cubic meters (5 cubic feet). NOTE: The air bag is not a serviceable item. Reaction Housing The reaction housing is a steel support for the inflator that provides a reaction surface for the passenger side air bag and is also used to attach the trim cover. It contains mounting brackets that attach the passenger side air bag module to the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Driver Side Air Bag Module > Page 10416 NOTE: The reaction housing is not a serviceable item. Trim Cover Its main function is to retain the air bag in the reaction housing during vehicle operation. The thermo-plastic trim cover is textured and painted to match the surface of the instrument panel. It is constructed with a moulded-in tear seam that separates when the air bag inflates, and hinges out of the way during deployment. NOTE: The trim cover is not a serviceable item. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Disposal Procedures Air Bag: Service and Repair Air Bag Disposal Procedures Air Bag Deployment - Remote WARNING: Always wear safety glasses when repairing an air bag vehicle and when handling an air bag. - Carry a live air bag with the bag and trim cover pointed away from your body. An accidental deployment will then deploy with a minimal chance of injury. - Remote deployment is to be performed outdoors with all personnel at least 20 feet away to make sure personal safety and due to the loud report which occurs when the air bag is deployed. - Do not place the driver side air bag module with the trim cover facing down, as the forces of the deploying air bag may cause it to ricochet and cause personal injury. 1. Remove the air bag module. 2. Cut and strip the ends of the two air bag module connector wires. 3. Connect a piece of wire to each air bag module connector wire. 4. Place the air bag module on a flat surface with the trim cover facing upward in an open outdoor area. 5. Obtain a distance 20 feet away from the air bag module. 6. Deploy the air bag by touching the other ends of the two wires to the terminals of a 12-volt battery. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Disposal Procedures > Page 10419 7. Allow at least ten minutes before approaching the deployed air bag to allow for cooling. 8. Dispose of the deployed air bag module in the same manner as any other part to be scrapped. Deployed Air Bags To service a vehicle with a deployed air bag, replace the deployed air bag with a new air bag module. The deployed air bag can be disposed of in the same manner as any part to be scrapped. Undeployed Air Bag- Faulty 1. Remove the faulty driver side air bag module or passenger side air bag module. NOTE: All faulty air bag modules have been placed on the Mandatory Return List. All discolored or damaged air bag modules should be treated the same as any faulty live air bag being returned. 2. When replacing the driver side air bag module, record the necessary information and return the faulty driver side air bag module to Ford Motor Company. NOTE: When replacing an air bag module, a prepaid return postcard is provided with the replacement air bag module. The serial number for the new part and the Vehicle Identification Number (VIN) must be recorded and sent to Ford Motor Company. 3. When replacing the passenger side air bag module, record the necessary information and return the faulty passenger side air bag module to Ford Motor Company. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Disposal Procedures > Page 10420 Air Bag: Service and Repair Removal and Installation Driver's Side REMOVAL NOTE: Refer to Service Precautions for Safety Information and Warnings. 1. Disconnect the battery cables. 2. Remove the driver side air bag module. NOTE: Make sure the wheels are in the straight-ahead position. 1 Remove the two back cover plugs. 2 Remove the two driver side air bag module screws. 3 Disconnect the horn electrical connector. 4 Disconnect the air bag sliding contact electrical connector. 5 Remove the driver side air bag module. 3. If the driver side air bag module is diagnosed as faulty, dispose of the air bag. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Disposal Procedures > Page 10421 Passenger's Side NOTE: Refer to Service Precautions for Safety Information and Warnings. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 1. Disconnect the battery cables. 2. Remove the instrument panel relay cover. 3. Remove the passenger side air bag module. 1 Remove the screws. 2 Disconnect the electrical connector. 3 Remove the passenger side air bag module. 4. If the passenger side air bag module is diagnosed as faulty, dispose of the air bag. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Disposal Procedures > Page 10422 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications Air Bag Control Module: Specifications Air Bag Diagnostic Monitor Screws ...................................................................................................................................... 10.2-13.8 Nm (91-123 lb in) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 10426 Air Bag Control Module: Locations Instrument Panel View The Air Bag Diagnostic Monitor is located behind right side (Passenger Side) of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 10427 Air Bag Control Module: Diagrams Air Bag Diagnostic Monitor (C208) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 10428 Air Bag Diagnostic Monitor (C209) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 10429 Air Bag Control Module: Service Precautions WARNING: Under no circumstances substitute another fuse value for the 10 AMP battery fuse. Any fuse other than 10 AMP may cause disarming failure and may result in danger to the occupants of the vehicle. Do not attempt to replace the 10 AMP battery fuse until the air bag system first has been deactivated . Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 10430 Air Bag Control Module: Description and Operation PURPOSE Performing system diagnostics is the main purpose of the air bag diagnostic monitor. The air bag diagnostic monitor continually monitors all air bag system components and wiring connections for possible faults when the ignition switch is in RUN position. OPERATION It does not deploy the air bags in the event of a collision. The air bag diagnostic monitor operates in the following manner: - If the air bag diagnostic monitor detects a fault in the air bag system, a Diagnostic Trouble Code (DTC) will be written to the air bag diagnostic monitor's Non-Volatile Random Access Memory (NVRAM). - This DTC will then be displayed on the air bag indicator lamp. - After servicing, the DTC may then be cleared from NVRAM. AIR BAG SYSTEM FUNCTIONS Other important features of the air bag diagnostic monitor and its functions within the system are described below. It is necessary that these key features and functions are well understood. - The air bag diagnostic monitor illuminates the air bag indicator for approximately six seconds when the ignition switch is in the RUN position and then turns the indicator off. This shows that the air bag indicator is operational. If the air bag indicator does not illuminate or the indicator stays on or flashes at any time, a fault has been detected by the air bag diagnostic monitor. - DTCs may not be displayed for approximately 30 seconds after the ignition switch is placed in the RUN position. This is the amount of time the air bag diagnostic monitor requires to perform all tests and verify system faults, if present. - Each diagnostic trouble code (a series of flashes and pauses of the air bag indicator) represents a two digit number. Each diagnostic trouble code is always displayed at least twice. For example, a diagnostic trouble code 32 is displayed as three flashes, followed by a one second pause, then two flashes, followed by a three second pause. - If a system fault is present and the air bag indicator is malfunctioning, an audible tone will be heard, indicating that system service is required. CAUTION: The thermal fuse does not blow (open) because of excessive current flowing through it. Do not attempt to jumper out the thermal fuse with a circuit breaker or any other type of fuse. - If a fault exists that makes unwanted air bag deployment possible, the air bag diagnostic monitor will attempt to remove deployment power by turning on a solid state switch to blow the 10A battery fuse 2. - If the 10 A battery fuse has successfully been blown by the air bag diagnostic monitor, the air bag diagnostic monitor will not attempt to blow it again until the proper fault has been repaired and cleared (see Diagnostic Trouble Code Clearing procedures for details). The air bag diagnostic monitor will store both the unwanted deployment DTC and the loss of deployment power DTC. The loss of deployment power DTC is the highest priority. - Diagnostic trouble codes are prioritized numerically so if two or more different faults occur at the same time, the fault having the highest priority will be displayed first. After that fault has been corrected, the next highest priority fault will be displayed. - The air bag diagnostic monitor includes an internal backup power supply. This feature provides sufficient backup power to deploy the air bag in the event that the battery or battery cables are damaged in an accident before the center air bag and front air bag sensors close. The backup power supply will deplete its stored energy approximately one minute after the positive battery cable is disconnected. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 10431 Air Bag Control Module: Service and Repair REMOVAL WARNING: To avoid accidental deployment and possible injury, the backup power supply must be depleted before repairing or replacing any air bag system components. To deplete the backup power supply energy, disconnect the battery to starter relay cable and wait one minute. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: The safing sensor is internal to the air bag diagnostic monitor and is not replaced separately. 1. Disconnect the battery cables. 2. Remove the RH cowl side trim panel. 3. Remove the air bag diagnostic monitor. 1 Disconnect the two electrical connectors. 2 Remove the four screws. 3 Remove the air bag diagnostic monitor. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Recalls: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement Technical Service Bulletin # 00B33 Date: 000301 Recall - Airbag Deactivation Shunt Replacement OWNER NOTIFICATION PROGRAM 00B33 Certain Vehicles In Which An Interim Airbag Deactivation Shunt Was Installed By A Ford Or Lincoln Mercury Dealer - Key Activated Airbag "On-Off" Switch Installation ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Refund Codes ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ VIN and Part Number List ^ Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Recalls: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 10440 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Recalls: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 10441 Attachment I - Administrative/Refund Code Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. NOTE: There are 99 vehicles involved in this program nationwide. Deactivation kits are currently available for 57 of these vehicles which are listed in Attachment IV. Only these 57 vehicles, which have an available kit, will be active in OASIS and the owners notified. As new kits become available, OASIS will be updated with new VINs and the owners notified. Consult your Master Parts Catalog for base number 14B385 to determine part numbers for new kits. PROMPTLY CORRECT Promptly correct all affected vehicles on the enclosed list. Please be sure to obtain the customer's authorization to remove the shunt and install the "On-Off" switch. Other eligible vehicles, identified by OASIS, which are brought to your dealership. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII Manual for claims preparation and submission information. RENTAL CARS Rental cars are not approved for this program. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Recalls: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 10442 LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this program. Order your parts requirement through normal order processing channels as noted in the table. PLEASE NOTE: There are 99 vehicles involved nationwide.Of these, 57 have a service part kit available now. Pans kits are in development for the 42 remaining vehicles. Attachment IV contains the VIN and part numbers for the 57 vehicles which have a service pan kit. This is not a list of VINs assigned to your Dealership. Chances are you will not see any of these vehicles. Please do not order parts unless contacted by a customer whose VIN appears in Attachment IV. Do not order for stock. DEALER PRICE For latest prices, check or call your: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information TECHNICAL INSTRUCTIONS: Instructions for removing the airbag shunt and installing the key activated "On-0ff" switch are included in each kit. Please follow the kit instructions carefully when servicing the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Recalls: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 10443 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Recalls: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 10444 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Recalls: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 10445 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Recalls: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 10446 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Recalls: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 10447 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Component Information > Description and Operation Dimmer Switch: Description and Operation The panel dimmer switch is integrated into the headlamp switch and controls the interior lamps by activating the interior lamp relay. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Deactivation Switch: > 01-16-6 > Aug > 01 > Recalls for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement Technical Service Bulletin # 00B33 Date: 000301 Recall - Airbag Deactivation Shunt Replacement OWNER NOTIFICATION PROGRAM 00B33 Certain Vehicles In Which An Interim Airbag Deactivation Shunt Was Installed By A Ford Or Lincoln Mercury Dealer - Key Activated Airbag "On-Off" Switch Installation ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Refund Codes ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ VIN and Part Number List ^ Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Deactivation Switch: > 01-16-6 > Aug > 01 > Recalls for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 10459 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Deactivation Switch: > 01-16-6 > Aug > 01 > Recalls for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 10460 Attachment I - Administrative/Refund Code Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. NOTE: There are 99 vehicles involved in this program nationwide. Deactivation kits are currently available for 57 of these vehicles which are listed in Attachment IV. Only these 57 vehicles, which have an available kit, will be active in OASIS and the owners notified. As new kits become available, OASIS will be updated with new VINs and the owners notified. Consult your Master Parts Catalog for base number 14B385 to determine part numbers for new kits. PROMPTLY CORRECT Promptly correct all affected vehicles on the enclosed list. Please be sure to obtain the customer's authorization to remove the shunt and install the "On-Off" switch. Other eligible vehicles, identified by OASIS, which are brought to your dealership. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII Manual for claims preparation and submission information. RENTAL CARS Rental cars are not approved for this program. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Deactivation Switch: > 01-16-6 > Aug > 01 > Recalls for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 10461 LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this program. Order your parts requirement through normal order processing channels as noted in the table. PLEASE NOTE: There are 99 vehicles involved nationwide.Of these, 57 have a service part kit available now. Pans kits are in development for the 42 remaining vehicles. Attachment IV contains the VIN and part numbers for the 57 vehicles which have a service pan kit. This is not a list of VINs assigned to your Dealership. Chances are you will not see any of these vehicles. Please do not order parts unless contacted by a customer whose VIN appears in Attachment IV. Do not order for stock. DEALER PRICE For latest prices, check or call your: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information TECHNICAL INSTRUCTIONS: Instructions for removing the airbag shunt and installing the key activated "On-0ff" switch are included in each kit. Please follow the kit instructions carefully when servicing the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Deactivation Switch: > 01-16-6 > Aug > 01 > Recalls for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 10462 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Deactivation Switch: > 01-16-6 > Aug > 01 > Recalls for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 10463 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Deactivation Switch: > 01-16-6 > Aug > 01 > Recalls for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 10464 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Deactivation Switch: > 01-16-6 > Aug > 01 > Recalls for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 10465 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Deactivation Switch: > 01-16-6 > Aug > 01 > Recalls for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 10466 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams Clock Spring Assembly Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 10470 Clockspring Assembly / Spiral Cable: Description and Operation PURPOSE The steering column has an air bag sliding contact to transfer electrical signals from the steering column to the steering wheel for the air bag system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 10471 Clockspring Assembly / Spiral Cable: Service and Repair NOTE: Refer to Service Precautions for Safety Information and Warnings. REMOVAL 1. Remove the driver side air bag module. 2. Remove the steering wheel. NOTE: Make sure the wheels are in the straight-ahead position. 3. Twist the tilt wheel handle and shank and remove. 4. Remove the lower steering column shroud. 1 Remove the screws. 2 Remove the steering column shroud. 5. Remove the ignition switch lock cylinder. 6. Carefully pry to release the clips and remove the steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 10472 7. Remove the upper steering column shroud. 8. If the (A) lock is missing, apply two (B) strips of masking tape across the air bag sliding contact and housing to prevent accidental rotation. NOTE: The air bag sliding contact has a lock that prevents accidental rotation when the steering wheel is removed. 9. Remove the key-in ignition warning indicator switch. 10. Disconnect the air bag sliding contact electrical connector and separate the air bag electrical connector from the bracket. 11. Pry the retaining clips loose. 12. Separate the wire from the two retaining clips holding wire to the column. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 10473 13. Remove the air bag sliding contact. - Feed the wiring harness through the instrument panel. INSTALLATION NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 1. If the lock is missing, the air bag sliding contact must be realigned by: Rotating the air bag sliding contact rotor counterclockwise until it stops. - Rotate two revolutions. - Install per instructions. NOTE: The air bag sliding contact has a lock that prevents rotation of the air bag sliding contact when the steering wheel is removed. 2. Properly orientate the air bag sliding contact. 1 The air bag electrical pigtail should point to the three o'clock position. 2 The dot on the steering shaft should be at the nine o'clock position. 3. Press at six, twelve, and three o'clock positions to seat the air bag sliding contact. 4. Rotate the wiring and secure into two wire clips. 5. Connect the two electrical connectors. Snap into the bracket. 6. Install the key-in ignition warning indicator switch. 7. If a new clock spring is used, remove the yellow anti-rotation tab. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 10474 8. Install the ignition lock cylinder. 9. Install the upper and lower steering column shrouds. 10. Install the steering column opening cover. 11. Install the tilt wheel handle and shank. 12. Install the steering wheel. NOTE: Ensure the front wheels are in the straight-ahead position before starting the installation procedure. 13. Install the driver side air bag module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Specifications Impact Sensor: Specifications Air Bag Sensor Screws ........................................................................................................................................................... 10.2-13.8 Nm (91-123 lb in) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Left Crash Sensor Impact Sensor: Locations Left Crash Sensor Engine View The Left Primary Crash Sensor is located at left front of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Left Crash Sensor > Page 10480 Impact Sensor: Locations Right Crash Sensor Engine View The Right Primary Crash Sensor is located at right front of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 10481 Impact Sensor: Description and Operation PURPOSE The front air bag sensors are electrical switches that react to frontal impacts according to direction and force. The primary sensors measure the crash severity. OPERATION Primary crash sensors are "hard-wired" to the air bags and operate in the following manner: - They discriminate between impacts that require air bag inflation and impacts that do not. - When an impact occurs that requires air bag inflation, the sensor contacts close, completing the electrical circuit necessary for system operation. - The safing sensor and one primary crash sensor must be activated simultaneously to inflate the air bag. The air bag system is designed to operate in frontal or front-angled collisions. The driver side air bag module and passenger side air bag module should activate in a crash with severe frontal deceleration, more severe than hitting a parked car of similar size and weight head-on at about 45 km/h (28 mph). Because the air bag system senses severity of the crash rather than vehicle speed, some frontal collisions at speeds above 45 km/h (28 mph) may not be severe enough to require air bag inflation. The sensors in the vehicle determine if air bag inflation is required in the following manner: 1. During severe frontal deceleration caused by an impact that decelerates the vehicle in the forward direction, both a radiator primary crash sensor and a safing sensor will activate. 2. When a primary and safing sensor are closed at the same time, electrical current will flow, igniting the driver side air bag module and passenger side air bag module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 10482 Impact Sensor: Service and Repair REMOVAL WARNING: - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag system is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. If damaged, the sensor should be replaced whether or not the air bag is deployed. - Repair is made by replacement only. If a part is replaced and the new part does not correct the condition, install the original part and perform the diagnostic procedure again. - To avoid accidental deployment and possible injury, the backup power supply must be depleted before repairing or replacing any air bag system components. To deplete the backup power supply energy, disconnect the battery to starter relay cable and wait one minute. 1. Disconnect the battery cables. 2. Remove the radiator air deflector. 1 Remove the push clips. 2 Remove the radiator air deflector. 3. Disconnect the air bag sensor electrical connector (RH shown, LH similar). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 10483 4. Remove the air bag sensor. 1 Remove the screws. 2 Remove the air bag sensor. INSTALLATION To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Safing Sensor, Air Bag > Component Information > Locations Safing Sensor: Locations Integral with Air Bag Diagnostic Monitor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Safing Sensor, Air Bag > Component Information > Locations > Page 10487 Safing Sensor: Description and Operation PURPOSE The safing sensor confirms the crash and is used to prevent inadvertent deployments possibly caused by a malfunction in the primary crash sensor circuits or crash sensors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Safing Sensor, Air Bag > Component Information > Locations > Page 10488 Safing Sensor: Service and Repair The safing sensor is internal to the air bag diagnostic module and is not replaced separately. Refer to Air Bag Diagnostic Module / Service and Repair. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Description and Operation > Driver Side Air Bag Module Side Air Bag: Description and Operation Driver Side Air Bag Module NOTE: The driver side air bag module is serviced as a complete assembly. DESCRIPTION The driver side air bag module is mounted in the center of the steering wheel and consists of the following components: Inflator - When the sensors close, signaling a crash, electrical current flows to the air bag inflator. - Inside the inflator, an igniter converts the current into thermal energy, causing ignition of the inflator gas generant. - This ignition reaction combusts the sodium azide/copper oxide gas generant in the inflator, producing nitrogen gas, which inflates the air bag. NOTE: The inflator assembly is not a serviceable item. Air Bag The air bag is constructed of neoprene coated nylon. It is 711 mm (28 inches) in diameter and fills completely in approximately 40 milliseconds. NOTE: The air bag is not a serviceable item. Mounting Plate and Retainer Ring The mounting plate and retainer ring attach and seal the air bag to the inflator. The mounting bracket and housing are also used to attach the trim cover and to mount the entire driver side air bag module to the steering wheel. NOTE: The mounting plate and retainer ring are not serviceable items. Steering Wheel Trim Cover The cover is an injection-moulded plastic component which encases the driver side air bag module. When the air bag is activated, tear seams moulded into the steering wheel trim cover separate to allow inflation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Description and Operation > Driver Side Air Bag Module > Page 10493 NOTE: The steering wheel trim cover is not a serviceable item. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Description and Operation > Driver Side Air Bag Module > Page 10494 Side Air Bag: Description and Operation Passenger Side Air Bag Module NOTE: The passenger side air bag module is serviced as a complete assembly. DESCRIPTION The passenger side air bag module is mounted in the RH position of the instrument panel above the glove compartment and consists of the following components: Inflator - As with the driver side air bag module, an igniter inside the inflator converts electrical energy to thermal energy, causing ignition of the gas generant. - The ignition reaction causes combustion of the sodium azide/iron oxide gas generant producing nitrogen to fill the bag. - Since the passenger side air bag is much larger than the driver air bag, it contains more gas generant in a different inflator configuration to produce more nitrogen gas. NOTE: The passenger side air bag inflator is not a serviceable item. Air Bag The passenger side air bag is constructed of ripstop nylon and fills to a volume of approximately 0.142 cubic meters (5 cubic feet). NOTE: The air bag is not a serviceable item. Reaction Housing The reaction housing is a steel support for the inflator that provides a reaction surface for the passenger side air bag and is also used to attach the trim cover. It contains mounting brackets that attach the passenger side air bag module to the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Description and Operation > Driver Side Air Bag Module > Page 10495 NOTE: The reaction housing is not a serviceable item. Trim Cover Its main function is to retain the air bag in the reaction housing during vehicle operation. The thermo-plastic trim cover is textured and painted to match the surface of the instrument panel. It is constructed with a moulded-in tear seam that separates when the air bag inflates, and hinges out of the way during deployment. NOTE: The trim cover is not a serviceable item. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side Air Bag Module Side Air Bag: Service and Repair Driver Side Air Bag Module REMOVAL NOTE: Refer to Service Precautions for Safety Information and Warnings. 1. Disconnect the battery cables. 2. Remove the driver side air bag module. NOTE: Make sure the wheels are in the straight-ahead position. 1 Remove the two back cover plugs. 2 Remove the two driver side air bag module screws. 3 Disconnect the horn electrical connector. 4 Disconnect the air bag sliding contact electrical connector. 5 Remove the driver side air bag module. 3. If the driver side air bag module is diagnosed as faulty, dispose of the air bag. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side Air Bag Module > Page 10498 Side Air Bag: Service and Repair Passenger Side Air Bag NOTE: Refer to Service Precautions for Safety Information and Warnings. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 1. Disconnect the battery cables. 2. Remove the instrument panel relay cover. 3. Remove the passenger side air bag module. 1 Remove the screws. 2 Disconnect the electrical connector. 3 Remove the passenger side air bag module. 4. If the passenger side air bag module is diagnosed as faulty, dispose of the air bag. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side Air Bag Module > Page 10499 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Testing and Inspection Malfunction Lamp / Indicator: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications Air Bag Control Module: Specifications Air Bag Diagnostic Monitor Screws ...................................................................................................................................... 10.2-13.8 Nm (91-123 lb in) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 10507 Air Bag Control Module: Locations Instrument Panel View The Air Bag Diagnostic Monitor is located behind right side (Passenger Side) of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 10508 Air Bag Control Module: Diagrams Air Bag Diagnostic Monitor (C208) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 10509 Air Bag Diagnostic Monitor (C209) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 10510 Air Bag Control Module: Service Precautions WARNING: Under no circumstances substitute another fuse value for the 10 AMP battery fuse. Any fuse other than 10 AMP may cause disarming failure and may result in danger to the occupants of the vehicle. Do not attempt to replace the 10 AMP battery fuse until the air bag system first has been deactivated . Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 10511 Air Bag Control Module: Description and Operation PURPOSE Performing system diagnostics is the main purpose of the air bag diagnostic monitor. The air bag diagnostic monitor continually monitors all air bag system components and wiring connections for possible faults when the ignition switch is in RUN position. OPERATION It does not deploy the air bags in the event of a collision. The air bag diagnostic monitor operates in the following manner: - If the air bag diagnostic monitor detects a fault in the air bag system, a Diagnostic Trouble Code (DTC) will be written to the air bag diagnostic monitor's Non-Volatile Random Access Memory (NVRAM). - This DTC will then be displayed on the air bag indicator lamp. - After servicing, the DTC may then be cleared from NVRAM. AIR BAG SYSTEM FUNCTIONS Other important features of the air bag diagnostic monitor and its functions within the system are described below. It is necessary that these key features and functions are well understood. - The air bag diagnostic monitor illuminates the air bag indicator for approximately six seconds when the ignition switch is in the RUN position and then turns the indicator off. This shows that the air bag indicator is operational. If the air bag indicator does not illuminate or the indicator stays on or flashes at any time, a fault has been detected by the air bag diagnostic monitor. - DTCs may not be displayed for approximately 30 seconds after the ignition switch is placed in the RUN position. This is the amount of time the air bag diagnostic monitor requires to perform all tests and verify system faults, if present. - Each diagnostic trouble code (a series of flashes and pauses of the air bag indicator) represents a two digit number. Each diagnostic trouble code is always displayed at least twice. For example, a diagnostic trouble code 32 is displayed as three flashes, followed by a one second pause, then two flashes, followed by a three second pause. - If a system fault is present and the air bag indicator is malfunctioning, an audible tone will be heard, indicating that system service is required. CAUTION: The thermal fuse does not blow (open) because of excessive current flowing through it. Do not attempt to jumper out the thermal fuse with a circuit breaker or any other type of fuse. - If a fault exists that makes unwanted air bag deployment possible, the air bag diagnostic monitor will attempt to remove deployment power by turning on a solid state switch to blow the 10A battery fuse 2. - If the 10 A battery fuse has successfully been blown by the air bag diagnostic monitor, the air bag diagnostic monitor will not attempt to blow it again until the proper fault has been repaired and cleared (see Diagnostic Trouble Code Clearing procedures for details). The air bag diagnostic monitor will store both the unwanted deployment DTC and the loss of deployment power DTC. The loss of deployment power DTC is the highest priority. - Diagnostic trouble codes are prioritized numerically so if two or more different faults occur at the same time, the fault having the highest priority will be displayed first. After that fault has been corrected, the next highest priority fault will be displayed. - The air bag diagnostic monitor includes an internal backup power supply. This feature provides sufficient backup power to deploy the air bag in the event that the battery or battery cables are damaged in an accident before the center air bag and front air bag sensors close. The backup power supply will deplete its stored energy approximately one minute after the positive battery cable is disconnected. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 10512 Air Bag Control Module: Service and Repair REMOVAL WARNING: To avoid accidental deployment and possible injury, the backup power supply must be depleted before repairing or replacing any air bag system components. To deplete the backup power supply energy, disconnect the battery to starter relay cable and wait one minute. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: The safing sensor is internal to the air bag diagnostic monitor and is not replaced separately. 1. Disconnect the battery cables. 2. Remove the RH cowl side trim panel. 3. Remove the air bag diagnostic monitor. 1 Disconnect the two electrical connectors. 2 Remove the four screws. 3 Remove the air bag diagnostic monitor. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Warning Relay > Component Information > Description and Operation Seat Belt Warning Relay: Description and Operation The driver safety belt incorporates a safety belt warning indicator switch, warning indicator and chime. The warning indicator and chime are reminders to fasten the safety belt. - If the safety belt is not buckled when the key is turned to the ON position, the warning indicator and chime will turn on for 4 to 8 seconds. - If the safety belt is buckled while the warning indicator is on and the chime is sounding, both the warning indicator and chime will turn off. - If the safety belt is buckled before the key is turned to the ON position, the warning indicator will come on for 4 to 8 seconds with no chime. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming Deactivation Procedure 1. Disconnect positive battery cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Wait one minute. This is the time required for backup power supply in air bag diagnostic monitor to deplete its stored energy. 3. Remove two back cover plugs and remove screw and washer assemblies retaining driver side air bag module to steering wheel. Disconnect horn electrical connector. Disconnect driver air bag sliding contact electrical connector. Remove driver side air bag module from vehicle. WARNING: Place air bag module on bench with trim cover facing up. 4. Connect Rotunda Air Bag Simulator 105-R0011 or equivalent to vehicle harness at top of steering column. 5. Remove passenger side air bag module. Install Rotunda Air Bag Simulator 105-00012 or equivalent on vehicle harness connector in place of passenger side air bag module. 6. Reconnect positive battery cable. Reactivation Procedure 1. Disconnect positive battery cable. WARNING: The air bag simulator must be removed and the air bag reconnected when the system is reactivated. 2. Wait one minute for backup power supply in air bag diagnostic monitor to deplete stored energy. 3. Remove air bag simulator from vehicle harness connector at top of steering column. 4. Reconnect driver side air bag module. 5. Position driver side air bag module on steering wheel and secure with two screw and washer assemblies (8 mm). Tighten screw and washer assemblies to 10-13 Nm (89-115 lb in). Install two back cover plugs. 6. Remove air bag simulator from vehicle harness connector on passenger side. Reconnect and install passenger side air bag module. 7. Reconnect positive battery cable. 8. Prove out system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 10521 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The check list below should be completed following diagnosis or service of any air bag system concern: 1. Are both air bag crash sensors connected and mounted to the vehicle? 2. Is 3-way connector at base of steering column connected? 3. Are the air bags or air bag simulators connected? 4. Is air bag diagnostic monitor connected? 5. Is vehicle battery connected? Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation Seat Belt: Service and Repair Removal and Installation Front - Captain's Chair REMOVAL 1. Remove the console panel. 2. Remove the passenger seat safety belt buckle. 1 Use Safety Belt Bolt Bit to remove the bolt. 2 Remove the buckle. 3. On power driver seats, remove the driver seat safety belt buckle. 1 Disconnect the safety belt warning indicator switch electrical connector. 2 Use Safety Belt Bolt Bit to remove the bolt. 3 Remove the buckle. 4. On manual driver seats, remove the driver side safety belt buckle. 1 Disconnect the safety belt warning indicator switch electrical connector. 2 Remove the nut. 3 Remove the buckle. INSTALLATION NOTE: Make sure the safety belt webbing is not twisted prior to installation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 10526 To install, reverse the removal procedure. - Check the restraint system for proper operation. 60% Portion REMOVAL 1. Remove the headrest. Insert pin into hole to release rod on both sides. 2. Remove the second row armrest. Remove the four bolts (two each side). 3. Remove the latch control cable from the seat back. Disconnect the cable from the seat back latch. Remove the screw. 4. Remove the flipper panel latch. Pry the latch apart. 5. Remove the flipper panel cover. 6. Remove the seat cushion support bar. 7. Remove the seat cushion from the seat back. 8. Remove the safety belt divider. 9. Remove the seat cover retainers. 10. Remove the safety belt buckle. 1 Use Safety Belt Bolt Bit to remove the bolt. 2 Remove the buckle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 10527 11. To install, reverse the removal procedure. 40/60 Split Bench Seat, Center and RH Passenger REMOVAL Remove the safety belt buckle assembly. 1 Use Safety Belt Bolt Bit to remove the two bolts. 2 Remove the assembly. INSTALLATION To install, reverse the removal procedure. - Check the restraint system for proper operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 10528 Third Row REMOVAL and INSTALLATION 1. Remove the LH lower pivot cover. 2. Remove the seat adjuster handle. 3. Remove the RH lower adjuster cover. 4. Remove the seat back from the seat cushion. 5. Remove the seat cushion cover and pad from the seat cushion frame. 6. Remove the seat cover from the seat cushion. 7. Remove the safety belts. 8. To install, reverse removal procedure. 40/60 Split Bench Seat, Center and RH Passenger REMOVAL Remove the front passenger safety belt. 1 Use T55 "Torx" Bit to remove the bolt. 2 Feed the belt through the seat cushion pocket and remove the belt. INSTALLATION To install, reverse the removal procedure. - Check the restraint system for proper operation. 40/60 Split Bench, Driver Seat REMOVAL Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 10529 Remove the driver seat safety belt buckle. NOTE: To ease removal, position the driver seat in its most rearward position and the passenger seat in its most forward position. 1 Disconnect the safety belt warning indicator switch electrical connector. 2 Use Safety Belt Bolt Bit to remove the bolt. 3 Remove the buckle. INSTALLATION To install, reverse the removal procedure. - Check the restraint system for proper operation. Front Seat REMOVAL NOTE: This procedure is for the LH side; RH side is similar. 1. Remove the safety belt guide bolt. 1 Lift the bolt cover. 2 Use Safety Belt Bolt Bit to remove the bolt. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 10530 2. Use Safety Belt Bolt Bit to remove the bolt. 3. Remove the B-pillar trim panel. 4. Remove the height adjuster cover. 5. Remove the shoulder safety belt height adjuster. 1 Use Safety Belt Bolt Bit to remove the bolts. 2 Remove the adjuster. INSTALLATION NOTE: Bolts should be started by hand. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 10531 To install, reverse the removal procedure. Rear REMOVAL NOTE: This procedure is for the LH side; RH side is similar. 1. Remove the bolt. 1 Lift the bolt cover. 2 Use Safety Belt Bolt Bit to remove the bolt. 2. Remove the C-pillar trim panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 10532 3. Remove the height adjuster cover. 4. Remove the shoulder safety belt height adjuster. 1 Use Safety Belt Bolt Bit to remove the bolts. 2 Remove the adjuster. INSTALLATION NOTE: Bolts should he started by hand. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 10533 Seat Belt: Service and Repair Service Procedures Height Adjuster With Stripped Weld Nuts 1. Remove the body pillar finish panel. 2. Use the half-inch drill provided in D-Ring Installation Kit to drill out the damaged threads in the upper pillar structure. 3. Apply a suitable lubricant to the M14x1.5 tap provided in D-Ring Installation Kit and tap new threads. NOTE: After each rotation, back off tap slightly to remove new cuttings and be sure to blow out any chips before proceeding. 4. Use a threaded insert provided in D-Ring Installation Kit and screw it into the retapped hole until it is slightly below the surface. 5. Use a hammer to lightly tap the installation tool provided in D-Ring Installation Kit several times to seat the insert keys. NOTE: If the two bolts on the height adjuster are not stripped, refer to height adjuster, installation procedure. If the bolts are stripped, replace the height adjuster. Post Collision Inspection WARNING: All safety belt assemblies including retractors, buckles, front seat belt buckle support assemblies (slide bar), if so equipped, child safety seat tether attachments, and attaching hardware should be inspected after any collision. All belt assemblies should be replaced unless a qualified technician finds the assemblies show no damage and operate properly. Belt assemblies not in use during a collision should also be inspected and replaced if either damage or improper operation is noted. Safety belt assemblies should be periodically inspected to make sure they have not become damaged and that they remain in proper operating condition, particularly if they have been subjected to severe stress. Before installing the new safety belt assembly, the safety belt attaching areas must be inspected for damage and distortion. If the attaching points are damaged and distorted, the sheet metal must be reworked back to its original shape and structural integrity. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 10534 Install the new safety belt(s) using the appropriate instructions. Perform Functional Test Procedure in Testing and Inspection. Front Safety Belt REMOVAL NOTE: This procedure is for the LH side; RH side is similar. 1. Remove the bolt. 1 Lift the bolt cover. 2 Use Safety Belt Bolt Bit to remove the bolt. 2. Use T55 "Torx" Bit to remove the anchor bolt. 3. Remove the B-pillar trim panel. 4. Remove the front safety belt retractor. 1 Use Safety Belt Bolt Bit to remove the bolt. 2 Remove the retractor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 10535 NOTE: Before retractor bolt is installed the retractor bracket should be positioned with the hole in the sheet metal. To install, reverse the removal procedure. Center Passenger REMOVAL 1. Remove the headrest. Insert pin into hole to release rod on both sides. 2. Remove the second row armrest. Remove the four bolts (two each side). 3. Remove the latch control cable from the seat back. Disconnect the cable from the seat back latch. Remove the screw. 4. Remove the flipper panel latch. Pry the latch apart. 5. Remove the flipper panel cover. 6. Remove the seat cushion support bar. 7. Remove the seat cushion from the seat back. 8. Remove the safety belt divider. 9. Remove the seat cover retainers. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 10536 10. Remove the safety belt retractor. 1 Use Safety Belt Bolt Bit to remove the bolt. 2 Remove the retractor. 11. To install, reverse the removal procedure. Driver Side REMOVAL NOTE: This procedure is for the LH side; RH side is similar. 1. Remove the safety belt guide bolt. 1 Lift the bolt cover. 2 Use Safety Belt Bolt Bit to remove the bolt. 2. Remove the quarter trim panel. 3. Use T55 "Torx" Bit to remove the bolt. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 10537 4. Remove the center safety belt retractor. 1 Use Safety Belt Bolt Bit to remove the bolt. 2 Remove the retractor. INSTALLATION To install, reverse the removal procedure. Third Row REMOVAL NOTE: This procedure is for the LH side; RH side is similar. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 10538 1. Remove the safety belt guide bolt cover. 2. Use Safety Belt Bolt Bit to remove the bolt. 3. Remove the quarter trim panel. NOTE: On vehicles equipped with auxiliary A/C, only the auxiliary A/C access panel needs to be removed and not the quarter trim panel. 4. Remove the rear safety belt retractor. 1 Use Safety Belt Bolt Bit to remove the bolt. 2 Remove the retractor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 10539 To install, reverse the removal procedure. Seat Belt With Anchor Plate Thread Damage 1. Remove the broken or stripped bolt and discard. 2. Drill out the internal threads in the safety belt anchor plate with a 27/64 inch drill. 3. Rethread the anchor plate with a 1/2-13 tap (seat belt). Parts Replacement Chart (Typical) 4. Install the attachment parts. Original parts are to be replaced with the repair parts indicated in the manufacturer's safety belt replacement guidelines. Unless otherwise specified, use original parts. Seat Belt Without Anchor Plate Thread Damage 1. Expose the suspect anchor point. NOTE: This procedure is for replacement of the weld nut. If the reinforcement is also missing, the body side must be removed and replaced. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Removal and Installation > Page 10540 2. Drill out two 8 mm (5/16 in) diameter access holes adjacent to the weld nut clearance hole. 3. Thread a length of copper welding wire through the clearance hole and position to secure the weld nut and washer. 4. Use MIG Wire Feed Welder and plug weld a 7/16 inch weld nut and standard washer in place at the two 8 mm (5/16 in) holes. 5. Metal finish as required. 6. Perform a certification test. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Specifications Seat Belt Buckle: Specifications Safety Belt Retractor Bolt .................................................................................................................... ........................................... 34-46 Nm (25-33 lb ft) Safety Belt Anchor Bolt ........................................................................................................................ .......................................... 34-46 Nm (25-33 lb ft) Driver Seat Safety Belt Buckle Nut ................................................................................................................................................ 30-40 Nm (23-29 lb ft) Driver Seat Safety Belt Buckle Bolt ............................................................................................................................................... 30-40 Nm (23-29 lb ft) Passenger Seat Safety Belt Buckle Bolt ......................................................................................................................................... 30-40 Nm (23-29 lb ft) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Specifications > Page 10544 Seat Belt Buckle: Locations Front Seat Buckles Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Specifications > Page 10545 2nd Row Seat Buckles Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Specifications > Page 10546 3rd Row Seat Buckles Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Captain's Chair Seat Belt Buckle: Service and Repair Captain's Chair REMOVAL 1. Remove the console panel. 2. Remove the passenger seat safety belt buckle. 1 Use Safety Belt Bolt Bit to remove the bolt. 2 Remove the buckle. 3. On power driver seats, remove the driver seat safety belt buckle. 1 Disconnect the safety belt warning indicator switch electrical connector. 2 Use Safety Belt Bolt Bit to remove the bolt. 3 Remove the buckle. 4. On manual driver seats, remove the driver side safety belt buckle. 1 Disconnect the safety belt warning indicator switch electrical connector. 2 Remove the nut. 3 Remove the buckle. INSTALLATION NOTE: Make sure the safety belt webbing is not twisted prior to installation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Captain's Chair > Page 10549 To install, reverse the removal procedure. - Check the restraint system for proper operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Captain's Chair > Page 10550 Seat Belt Buckle: Service and Repair Rear Seat Belt Buckle 60% Portion REMOVAL 1. Remove the headrest. Insert pin into hole to release rod on both sides. 2. Remove the second row armrest. Remove the four bolts (two each side). 3. Remove the latch control cable from the seat back. Disconnect the cable from the seat back latch. Remove the screw. 4. Remove the flipper panel latch. Pry the latch apart. 5. Remove the flipper panel cover. 6. Remove the seat cushion support bar. 7. Remove the seat cushion from the seat back. 8. Remove the safety belt divider. 9. Remove the seat cover retainers. 10. Remove the safety belt buckle. 1 Use Safety Belt Bolt Bit to remove the bolt. 2 Remove the buckle. 11. To install, reverse the removal procedure. 40/60 Split Bench Seat, Center and RH Passenger REMOVAL Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Captain's Chair > Page 10551 Remove the safety belt buckle assembly. 1 Use Safety Belt Bolt Bit to remove the two bolts. 2 Remove the assembly. INSTALLATION To install, reverse the removal procedure. - Check the restraint system for proper operation. Third Row REMOVAL and INSTALLATION 1. Remove the LH lower pivot cover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Captain's Chair > Page 10552 2. Remove the seat adjuster handle. 3. Remove the RH lower adjuster cover. 4. Remove the seat back from the seat cushion. 5. Remove the seat cushion cover and pad from the seat cushion frame. 6. Remove the seat cover from the seat cushion. 7. Remove the safety belts. 8. To install, reverse removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Captain's Chair > Page 10553 Seat Belt Buckle: Service and Repair Removal and Installation Driver Seat REMOVAL Remove the driver seat safety belt buckle. NOTE: To ease removal, position the driver seat in its most rearward position and the passenger seat in its most forward position. 1 Disconnect the safety belt warning indicator switch electrical connector. 2 Use Safety Belt Bolt Bit to remove the bolt. 3 Remove the buckle. INSTALLATION To install, reverse the removal procedure. - Check the restraint system for proper operation. Center and RH Passenger REMOVAL Remove the front passenger safety belt. 1 Use T55 "Torx" Bit to remove the bolt. 2 Feed the belt through the seat cushion pocket and remove the belt. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Captain's Chair > Page 10554 To install, reverse the removal procedure. - Check the restraint system for proper operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information > Description and Operation Seat Belt Extension: Description and Operation In certain cases, the safety belt may be too short even when it is fully extended. About 20 cm (8 in) can be added to the belt length by using a safety belt extension. Safety belt extensions are available through the dealership parts department. Safety belt extensions are only available with black webbing. As well, the standard buckle must be from the same manufacturer as the belt system to which it is attached. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Specifications Seat Belt Height Adjuster: Specifications Safety Belt Height Adjuster ............................................................................................................................................................ 34-46 Nm (25-33 lb ft) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Front Safety Belt Seat Belt Height Adjuster: Service and Repair Front Safety Belt REMOVAL NOTE: This procedure is for the LH side; RH side is similar. 1. Remove the safety belt guide bolt. 1 Lift the bolt cover. 2 Use Safety Belt Bolt Bit to remove the bolt. 2. Use Safety Belt Bolt Bit to remove the bolt. 3. Remove the B-pillar trim panel. 4. Remove the height adjuster cover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Front Safety Belt > Page 10563 5. Remove the shoulder safety belt height adjuster. 1 Use Safety Belt Bolt Bit to remove the bolts. 2 Remove the adjuster. INSTALLATION NOTE: Bolts should be started by hand. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Front Safety Belt > Page 10564 Seat Belt Height Adjuster: Service and Repair Removal and Installation REMOVAL NOTE: This procedure is for the LH side; RH side is similar. 1. Remove the bolt. 1 Lift the bolt cover. 2 Use Safety Belt Bolt Bit to remove the bolt. 2. Remove the C-pillar trim panel. 3. Remove the height adjuster cover. 4. Remove the shoulder safety belt height adjuster. 1 Use Safety Belt Bolt Bit to remove the bolts. 2 Remove the adjuster. INSTALLATION NOTE: Bolts should he started by hand. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Front Safety Belt > Page 10565 To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation The GEM controls the Driver safety belt not fastened warning lamp. The safety belt warning lamp warns that the safety belt is not fastened. The safety belt warning lamp illuminates when it is grounded and turns OFF when the circuit is open. The safety belt warning lamp will be illuminated when: - Safety belt is not fastened and the ignition switch is turned from the OFF/LOCK or ACC to the RUN or START position. The safety belt warning lamp will turn off when: - Safety belt fastened. - Ignition switch is switched from the RUN or START to the OFF/LOCK or ACC position. - After lamp is illuminated for 61 seconds. The safety belt warning lamp inputs are: - Ignition switch START position (battery potential when in START). - Ignition switch RUN position (battery potential on both RUN and RUN/ACC inputs). - Driver safety belt switch (grounded when not fastened, open circuit when fastened). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Description and Operation > Page 10569 Seat Belt Reminder Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Specifications Seat Belt Retractor: Specifications Safety Belt Retractor Bolt .................................................................................................................... ........................................... 34-46 Nm (25-33 lb ft) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Specifications > Page 10573 Seat Belt Retractor: Locations Front Seat Retractors and Tongues Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Specifications > Page 10574 2nd Row Seat Retractors and Tongues Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Specifications > Page 10575 3rd Row Seat Retractors and Tongues Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Specifications > Page 10576 Seat Belt Retractor: Description and Operation NOTE: When replacing an Automatic Locking Retraction (ALR) equipped retractor, the retractor should be checked to make sure it is not in the ALR mode after installation. All outboard continuous-loop, three-point retractor systems, except the drive reposition, are equipped with the ALR system. This system is used when locking a child in an outboard seating position. The ALR system is automatically engaged when the webbing is fully extracted from the retractor. As the webbing is retracted back onto the spool, an audible clicking sound is made indicating the retractor is in the ALR mode. The retractor will not lock while the webbing is retracting onto the spool. As soon as the webbing stops, the retractor will lock. The ALR mode is automatically disengaged when most of the webbing is retracted back onto the spool. The ALR mode is disengaged when the audible clicking sound ceases and the webbing is free to move in or out of the retractor indicating a normal mode of operation. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt, Retractor and Tongue Seat Belt Retractor: Service and Repair Front Seat Belt, Retractor and Tongue REMOVAL NOTE: This procedure is for the LH side; RH side is similar. 1. Remove the bolt. 1 Lift the bolt cover. 2 Use Safety Belt Bolt Bit to remove the bolt. 2. Use T55 "Torx" Bit to remove the anchor bolt. 3. Remove the B-pillar trim panel. 4. Remove the front safety belt retractor. 1 Use Safety Belt Bolt Bit to remove the bolt. 2 Remove the retractor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt, Retractor and Tongue > Page 10579 NOTE: Before retractor bolt is installed the retractor bracket should be positioned with the hole in the sheet metal. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt, Retractor and Tongue > Page 10580 Seat Belt Retractor: Service and Repair Rear Seat Belt, Retractor and Tongue Center Passenger REMOVAL 1. Remove the headrest. Insert pin into hole to release rod on both sides. 2. Remove the second row armrest. Remove the four bolts (two each side). 3. Remove the latch control cable from the seat back. Disconnect the cable from the seat back latch. Remove the screw. 4. Remove the flipper panel latch. Pry the latch apart. 5. Remove the flipper panel cover. 6. Remove the seat cushion support bar. 7. Remove the seat cushion from the seat back. 8. Remove the safety belt divider. 9. Remove the seat cover retainers. 10. Remove the safety belt retractor. 1 Use Safety Belt Bolt Bit to remove the bolt. 2 Remove the retractor. 11. To install, reverse the removal procedure. Driver Side REMOVAL NOTE: This procedure is for the LH side; RH side is similar. 1. Remove the safety belt guide bolt. 1 Lift the bolt cover. 2 Use Safety Belt Bolt Bit to remove the bolt. 2. Remove the quarter trim panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt, Retractor and Tongue > Page 10581 3. Use T55 "Torx" Bit to remove the bolt. 4. Remove the center safety belt retractor. 1 Use Safety Belt Bolt Bit to remove the bolt. 2 Remove the retractor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt, Retractor and Tongue > Page 10582 To install, reverse the removal procedure. Third Row REMOVAL NOTE: This procedure is for the LH side; RH side is similar. 1. Remove the safety belt guide bolt cover. 2. Use Safety Belt Bolt Bit to remove the bolt. 3. Remove the quarter trim panel. NOTE: On vehicles equipped with auxiliary A/C, only the auxiliary A/C access panel needs to be removed and not the quarter trim panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt, Retractor and Tongue > Page 10583 4. Remove the rear safety belt retractor. 1 Use Safety Belt Bolt Bit to remove the bolt. 2 Remove the retractor. INSTALLATION To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Warning Relay > Component Information > Description and Operation Seat Belt Warning Relay: Description and Operation The driver safety belt incorporates a safety belt warning indicator switch, warning indicator and chime. The warning indicator and chime are reminders to fasten the safety belt. - If the safety belt is not buckled when the key is turned to the ON position, the warning indicator and chime will turn on for 4 to 8 seconds. - If the safety belt is buckled while the warning indicator is on and the chime is sounding, both the warning indicator and chime will turn off. - If the safety belt is buckled before the key is turned to the ON position, the warning indicator will come on for 4 to 8 seconds with no chime. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Recalls for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement Technical Service Bulletin # 00B33 Date: 000301 Recall - Airbag Deactivation Shunt Replacement OWNER NOTIFICATION PROGRAM 00B33 Certain Vehicles In Which An Interim Airbag Deactivation Shunt Was Installed By A Ford Or Lincoln Mercury Dealer - Key Activated Airbag "On-Off" Switch Installation ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Refund Codes ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ VIN and Part Number List ^ Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Recalls for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 10596 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Recalls for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 10597 Attachment I - Administrative/Refund Code Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. NOTE: There are 99 vehicles involved in this program nationwide. Deactivation kits are currently available for 57 of these vehicles which are listed in Attachment IV. Only these 57 vehicles, which have an available kit, will be active in OASIS and the owners notified. As new kits become available, OASIS will be updated with new VINs and the owners notified. Consult your Master Parts Catalog for base number 14B385 to determine part numbers for new kits. PROMPTLY CORRECT Promptly correct all affected vehicles on the enclosed list. Please be sure to obtain the customer's authorization to remove the shunt and install the "On-Off" switch. Other eligible vehicles, identified by OASIS, which are brought to your dealership. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII Manual for claims preparation and submission information. RENTAL CARS Rental cars are not approved for this program. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Recalls for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 10598 LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this program. Order your parts requirement through normal order processing channels as noted in the table. PLEASE NOTE: There are 99 vehicles involved nationwide.Of these, 57 have a service part kit available now. Pans kits are in development for the 42 remaining vehicles. Attachment IV contains the VIN and part numbers for the 57 vehicles which have a service pan kit. This is not a list of VINs assigned to your Dealership. Chances are you will not see any of these vehicles. Please do not order parts unless contacted by a customer whose VIN appears in Attachment IV. Do not order for stock. DEALER PRICE For latest prices, check or call your: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information TECHNICAL INSTRUCTIONS: Instructions for removing the airbag shunt and installing the key activated "On-0ff" switch are included in each kit. Please follow the kit instructions carefully when servicing the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Recalls for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 10599 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Recalls for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 10600 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Recalls for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 10601 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Recalls for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 10602 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Recalls for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 10603 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement Technical Service Bulletin # 00B33 Date: 000301 Recall - Airbag Deactivation Shunt Replacement OWNER NOTIFICATION PROGRAM 00B33 Certain Vehicles In Which An Interim Airbag Deactivation Shunt Was Installed By A Ford Or Lincoln Mercury Dealer - Key Activated Airbag "On-Off" Switch Installation ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Refund Codes ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ VIN and Part Number List ^ Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 10609 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 10610 Attachment I - Administrative/Refund Code Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. NOTE: There are 99 vehicles involved in this program nationwide. Deactivation kits are currently available for 57 of these vehicles which are listed in Attachment IV. Only these 57 vehicles, which have an available kit, will be active in OASIS and the owners notified. As new kits become available, OASIS will be updated with new VINs and the owners notified. Consult your Master Parts Catalog for base number 14B385 to determine part numbers for new kits. PROMPTLY CORRECT Promptly correct all affected vehicles on the enclosed list. Please be sure to obtain the customer's authorization to remove the shunt and install the "On-Off" switch. Other eligible vehicles, identified by OASIS, which are brought to your dealership. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII Manual for claims preparation and submission information. RENTAL CARS Rental cars are not approved for this program. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 10611 LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this program. Order your parts requirement through normal order processing channels as noted in the table. PLEASE NOTE: There are 99 vehicles involved nationwide.Of these, 57 have a service part kit available now. Pans kits are in development for the 42 remaining vehicles. Attachment IV contains the VIN and part numbers for the 57 vehicles which have a service pan kit. This is not a list of VINs assigned to your Dealership. Chances are you will not see any of these vehicles. Please do not order parts unless contacted by a customer whose VIN appears in Attachment IV. Do not order for stock. DEALER PRICE For latest prices, check or call your: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information TECHNICAL INSTRUCTIONS: Instructions for removing the airbag shunt and installing the key activated "On-0ff" switch are included in each kit. Please follow the kit instructions carefully when servicing the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 10612 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 10613 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 10614 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 10615 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Deactivation Switch: > 00B33 > Mar > 00 > Recall - Airbag Deactivation Shunt Replacement > Page 10616 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications Impact Sensor: Specifications Air Bag Sensor Screws ........................................................................................................................................................... 10.2-13.8 Nm (91-123 lb in) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Crash Sensor Impact Sensor: Locations Left Crash Sensor Engine View The Left Primary Crash Sensor is located at left front of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Crash Sensor > Page 10622 Impact Sensor: Locations Right Crash Sensor Engine View The Right Primary Crash Sensor is located at right front of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 10623 Impact Sensor: Description and Operation PURPOSE The front air bag sensors are electrical switches that react to frontal impacts according to direction and force. The primary sensors measure the crash severity. OPERATION Primary crash sensors are "hard-wired" to the air bags and operate in the following manner: - They discriminate between impacts that require air bag inflation and impacts that do not. - When an impact occurs that requires air bag inflation, the sensor contacts close, completing the electrical circuit necessary for system operation. - The safing sensor and one primary crash sensor must be activated simultaneously to inflate the air bag. The air bag system is designed to operate in frontal or front-angled collisions. The driver side air bag module and passenger side air bag module should activate in a crash with severe frontal deceleration, more severe than hitting a parked car of similar size and weight head-on at about 45 km/h (28 mph). Because the air bag system senses severity of the crash rather than vehicle speed, some frontal collisions at speeds above 45 km/h (28 mph) may not be severe enough to require air bag inflation. The sensors in the vehicle determine if air bag inflation is required in the following manner: 1. During severe frontal deceleration caused by an impact that decelerates the vehicle in the forward direction, both a radiator primary crash sensor and a safing sensor will activate. 2. When a primary and safing sensor are closed at the same time, electrical current will flow, igniting the driver side air bag module and passenger side air bag module. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 10624 Impact Sensor: Service and Repair REMOVAL WARNING: - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag system is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. If damaged, the sensor should be replaced whether or not the air bag is deployed. - Repair is made by replacement only. If a part is replaced and the new part does not correct the condition, install the original part and perform the diagnostic procedure again. - To avoid accidental deployment and possible injury, the backup power supply must be depleted before repairing or replacing any air bag system components. To deplete the backup power supply energy, disconnect the battery to starter relay cable and wait one minute. 1. Disconnect the battery cables. 2. Remove the radiator air deflector. 1 Remove the push clips. 2 Remove the radiator air deflector. 3. Disconnect the air bag sensor electrical connector (RH shown, LH similar). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 10625 4. Remove the air bag sensor. 1 Remove the screws. 2 Remove the air bag sensor. INSTALLATION To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Safing Sensor, Air Bag > Component Information > Locations Safing Sensor: Locations Integral with Air Bag Diagnostic Monitor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Safing Sensor, Air Bag > Component Information > Locations > Page 10629 Safing Sensor: Description and Operation PURPOSE The safing sensor confirms the crash and is used to prevent inadvertent deployments possibly caused by a malfunction in the primary crash sensor circuits or crash sensors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Safing Sensor, Air Bag > Component Information > Locations > Page 10630 Safing Sensor: Service and Repair The safing sensor is internal to the air bag diagnostic module and is not replaced separately. Refer to Air Bag Diagnostic Module / Service and Repair. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Accessory Delay Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 10636 Junction Box Fuse/Relay Panel (Part 1 Of 2) The Accessory Delay Relay is located in the junction box fuse/relay panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Mast > Component Information > Specifications Antenna Mast: Specifications Antenna Base Screws ......................................................................................................................... .......................................... 1.6-2.2 Nm (14-19 In Lb) Antenna Mast ................................................... ............................................................................................................................ 3.4-3.6 Nm (30-31 In Lb) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair Antenna Cable: Service and Repair REMOVAL 1. Remove the front wheel opening moulding. 1. Remove the one pushpin. 2. Remove the four screws. 3. Carefully pry the wheel opening moulding to release the nine clips. 2. Remove the inner splash shield. 1. Remove the five screws. 2. Pull the inner fender splash shield to release the three clips. 3. Disconnect the radio antenna lead-in cable from the antenna base. 4. Remove the radio chassis. 5. Push the radio antenna lead-in cable into the passenger compartment. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Page 10645 1. Disconnect the radio antenna lead-in cable from the clip. 2. Push the grommet into the passenger compartment. 3. Push the radio antenna lead-in cable into the passenger compartment. 6. Remove the radio antenna lead-in cable. 1. Disconnect the cable clips from the lower metal I/P channel. 2. Disconnect the cable clip between the I/P channel and the radio end of cable. 3. Remove the radio antenna lead-in cable from under the instrument panel. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Specifications Alarm Module: Specifications Passive Anti-Theft System Module Screws ............................................................................................................................... 4.5-6.3 Nm (41-56.2 In Lb) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Anti-Theft Transceiver Module Alarm Module: Locations Anti-Theft Transceiver Module Instrument Panel View The Anti Theft-Transceiver Module is located behind the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Anti-Theft Transceiver Module > Page 10652 Alarm Module: Locations Passive Anti-Theft System Module Body View The Passive Anti-Theft System Module is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Anti-Theft Transceiver Module > Page 10653 Alarm Module: Locations Remote Anti-Theft Personality Module Body Views Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Anti-Theft Transceiver Module > Page 10654 The Remote Anti-Theft Personality Module is located behind left side of instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Controller Module Passive Anti-Theft System Control Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Controller Module > Page 10657 Anti-Theft Transceiver Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Controller Module > Page 10658 Alarm Module: Diagrams Remote Anti-Theft Personality Module Remote Anti-Theft Personality Module (C257) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Controller Module > Page 10659 Remote Anti-Theft Personality Module (C256) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 10660 Alarm Module: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the PATS module. 1. Disconnect the electrical connector. 2. Remove the two screws. 3. Remove the PATS module. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transmitter > Component Information > Technical Service Bulletins > Remote Antitheft Personality Transmitter - Reprogramming Alarm System Transmitter: Technical Service Bulletins Remote Antitheft Personality Transmitter Reprogramming Article No. 97-11-5 05/27/97 REMOTE ANTI-THEFT PERSONALITY (RAP) TRANSMITTERS - REPROGRAMMING INFORMATION FORD: 1996-97 TAURUS 1997-98 ESCORT LINCOLN-MERCURY: 1996-97 SABLE 1997-98 TRACER LIGHT TRUCK: 1995-97 EXPLORER, RANGER 1996-98 WINDSTAR 1997 EXPEDITION, F-150, MOUNTAINEER 1998 NAVIGATOR ISSUE: This TSB article contains information on reprogramming Remote Anti-Theft Personality (RAP) transmitters and how to diagnose if the transmitter needs reprogramming. ACTION: Refer to the following text for Diagnostic and Reprogramming information. DIAGNOSTIC INFORMATION If any one, but not all, remote entry transmitter button performs a function properly, then that transmitter is already programmed to the receiver module and does NOT require reprogramming. Check the functions that do not operate properly on the vehicle itself by referring to the appropriate model/year Service Manual. If a remote entry transmitter battery requires replacement, the transmitter does NOT require reprogramming. The transmitters use an industry standard battery No. 2016 - 3 volt. Alternative battery manufacturer sources are Duracell # CR2016; Radio Shack # CR2016H or # BR2016H; and Sony # CR2016. If there is reduced range performance or the transmitter will only function close to the vehicle, make sure the external antenna connection is made to the receiver module (if equipped). REPROGRAMMING INFORMATION NOTE: WHEN ENTERING PROGRAM MODE, ONCE THE FIRST TRANSMITTER BUTTON IS PRESSED, THE RAP MODULE ERASES ALL PREVIOUSLY STORED TRANSMITTER CODES IN MEMORY. ALL TRANSMITTERS MUST BE PRESENT AT THE SAME TIME TO BE PROGRAMMED TO THE VEHICLE, WITH A MAXIMUM OF FOUR (4) TRANSMITTERS BEING ABLE TO BE PROGRAMMED. NOTE: WHEN PROGRAM MODE HAS BEEN ENTERED, ANY TRANSMITTER FUNCTIONED WITHIN 30 METERS OF THE VEHICLE CAN BE PROGRAMMED TO THAT VEHICLE, AND IN THE PROCESS, ERASE OUT ALL PREVIOUSLY STORED TRANSMITTER CODES. MOST FORD TRANSMITTERS CAN OPERATE IN ANY VEHICLE. 1. Enter Program Mode: a. For Model Years 1995-97: Cycle the ignition from OFF to RUN/ACC five (5) times within 10 seconds, ending in RUN/ACC, or cycle the ignition from OFF to START three (3) times within 10 seconds, ending in RUN. The power door locks should cycle LOCK to UNLOCK to confirm entrance into Program Mode. b. For Model Year 1998 (Windstar/Escort/Trace/Navigator): Cycle the ignition from OFF to RUN/ACC eight (8) times within 10 seconds, ending in RUN/ACC, or cycle the ignition from OFF to START four (4) times within 10 seconds, ending in RUN. The power door locks should cycle LOCK to Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transmitter > Component Information > Technical Service Bulletins > Remote Antitheft Personality Transmitter - Reprogramming > Page 10665 UNLOCK to confirm entrance into Program Mode. 2. Press any button on a remote entry transmitter. The power door locks should cycle LOCK then UNLOCK to acknowledge transmitter code. 3. Repeat Step 2 for any additional remote entry transmitters that need to be programmed to the vehicle. 4. Turn the ignition switch to OFF to exit Program Mode. To confirm Program Mode has been exited, the power door locks will cycle LOCK then UNLOCK one last time. FOR ESCORT/TRACER VEHICLES ONLY: NOTE: ESCORT/TRACER OFFERS TWO SYSTEMS FOR NORTH AMERICA AND ONE FOR MEXICO ONLY. FOR NORTH AMERICA, THERE IS A FULL FOUR-DOOR REMOTE ENTRY WITH PERIMETER ANTI-THEFT SYSTEM AND A SINGLE DOOR REMOTE ENTRY SYSTEM WITH NO PERIMETER ANTI-THEFT. THE SINGLE DOOR REMOTE ENTRY SYSTEM OPERATES THE DRIVER'S DOOR ONLY AND NOT THE PASSENGER DOORS. NOTE: THE RHEOSTAT DIMMER SWITCH MAY CAUSE RADIO FREQUENCY INTERFERENCE ISSUES WITH THE REMOTE ENTRY TRANSMITTERS. WHEN FUNCTIONING TRANSMITTERS, MAKE SURE THE EXTERIOR LIGHTS ARE OFF TO VERIFY PROPER FUNCTIONALITY. INFORM CUSTOMERS OF POSSIBLE ERRATIC/NO OPERATION OF REMOTE TRANSMITTERS WHEN THE SWITCH IS TURNED ON. CAUTION: LOOK FOR DOOR LOCK ACTUATOR RODS IN THE DRIVER AND PASSENGER DOORS NOT BEING CONNECTED PROPERLY. THIS IS ESPECIALLY IMPORTANT ON SINGLE DOOR REMOTE ENTRY SYSTEM VEHICLES WHERE ONLY THE DRIVER'S DOOR HAS A POWER DOOR LOCK ACTUATOR. TO DETERMINE IF THE TRANSMITTER IS OPERATING PROPERLY, PRESS THE TRUNK BUTTON TO VERIFY IT RELEASES THE TRUNK. NOTE: WITH MANUAL TRANSMISSIONS, IT MAY BE DIFFICULT TO PERFORM THE PROGRAM MODE SEQUENCE DUE TO THE IGNITION LOCKING FEATURE. IT WOULD BE EASIER TO CYCLE THE IGNITION FROM OFF TO ACC RATHER THAN TO RUN. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000, 203000, 205000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Specifications Keyless Entry Module: Specifications RAP Module Nuts ................................................................................................................................ ...................................................... 7 Nm (62.4 in lb) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Specifications > Page 10670 Keyless Entry Module: Locations Body Views Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Specifications > Page 10671 The Remote Anti-Theft Personality Module is located behind left side of instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Specifications > Page 10672 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect the C257 and C256 Remote Anti-theft Personality (RAP) module electrical connectors. 2. Disconnect the antenna connector. 3. Remove the RAP module nuts and the RAP module. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Description and Operation Keyless Entry Transmitter: Description and Operation NOTE: The remote entry features will not function when the ignition switch is in the RUN or ACC position. The keyless entry remote transmitters: ^ Are reprogrammable. ^ Must be set at the same time. To unlock the driver door: ^ Press the UNLOCK button on the keyless entry remote transmitter. NOTE: If more than five seconds have elapsed since the first press of the UNLOCK button, pressing the UNLOCK button again will only unlock the driver door a second time. To unlock all doors: ^ Press the UNLOCK button on the keyless entry remote transmitter a second time, within five seconds of the first unlock. To lock all doors: ^ Press the LOCK button on the keyless entry remote transmitter once. ^ Press the LOCK button again, within five seconds of the first press. The horn will chirp once if the doors have locked and all doors are closed. The horn will chirp twice if a door is open, indicating that the anti-theft system will not arm until all the doors are closed. To confirm that the doors have been locked: ^ Press the LOCK button again, within five seconds of the first press. The horn will chirp once. To activate the panic alarm: ^ Press the red PANIC button on the keyless entry remote transmitter. The horn will sound and the headlamps and exterior lamps will flash for a maximum of two minutes and 45 seconds. To deactivate the panic alarm: ^ Press the red PANIC button again on the keyless entry remote transmitter. ^ Turn the ignition switch to RUN/ACC. Inputs and Outputs The RAP module receives input from the following components for electronic door lock system operation: ^ Keyless entry remote transmitters. ^ Door ajar output from the GEM. ^ Brake on/off switch. ^ Transmission range (TR) sensor. ^ Remote entry antenna. The RAP module distributes output to the following for the electronic door lock system: ^ Driver unlock relay. ^ All unlock relay. ^ All lock relay. ^ Horn relay. ^ Headlamp relay. ^ Park lamp relay. ^ Illuminated entry request output to the GEM. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Description and Operation > Page 10676 Keyless Entry Transmitter: Service and Repair NOTE: All keyless entry remote transmitters must be set at the same time. To program (or reprogram) the keyless entry remote transmitters into the RAP module, perform the following steps: 1. Turn the ignition switch from OFF to RUN five times within ten seconds, ending in RUN. If the RAP module has successfully entered program mode, it will lock and then unlock all doors. 2. Press any button on a keyless entry remote transmitter, and the doors will lock and then unlock to confirm that each keyless entry remote transmitter has been programmed. 3. If the door locks do not respond for any keyless entry remote transmitter, wait several seconds and press the button again. If the door locks still fail to respond, refer to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures 4. Turn the ignition switch to the OFF position, or wait up to five minutes after step 2, to exit program mode. If a keyless entry remote transmitter has been programmed (or reprogrammed), the RAP module will lock and unlock all doors one last time to confirm. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Service and Repair Lock Cylinder Switch: Service and Repair REMOVAL NOTE: In the images, the steering wheel is removed for clarity. 1. If equipped, twist the tilt wheel handle and shank and remove. 2. Remove the lower steering column shroud. 1. Remove the three lower steering column shroud screws. 2. Remove the lower steering column shroud. 3. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to RUN position. 2. Push the (A) ignition switch lock cylinder release tab with a punch while pulling out the (B) ignition switch lock cylinder. 4. Carefully pry to release the four clips and remove the steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Service and Repair > Page 10680 5. Remove the upper steering column shroud. 6. Remove the upper instrument panel steering column cover. 7. Remove the ignition lock anti-theft switch. 1. Disconnect the electrical connector. 2. Remove the ignition lock anti-theft switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Testing and Inspection Security Lamp/Indicator: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Specifications General Module: Specifications GEM Screws ........................................................................................................................................ .......................................... 0.9-1.3 Nm (8-12 In Lb) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Specifications > Page 10687 General Module: Locations Instrument Panel View The Generic Electronic Module is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions General Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10690 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10691 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10692 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10693 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10694 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10695 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10696 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10697 General Module: Connector Views Generic Electronic Module (C239) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10698 Generic Electronic Module (C267) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10699 Generic Electronic Module (C240 ) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10700 Generic Electronic Module (C241) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10701 General Module: Electrical Diagrams Generic Electronic Module (Part 1 Of 5) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10702 Generic Electronic Module (Part 2 Of 5) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10703 Generic Electronic Module (Part 3 Of 5) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10704 Generic Electronic Module (Part 4 Of 5) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10705 Generic Electronic Module (Part 5 Of 5) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Page 10706 General Module: Description and Operation GEM Circuit Protection Short Circuit/Battery Voltage The Generic Electronic Module (GEM) outputs are designed to withstand continuous exposure to a short circuit to ground or battery voltage without being damaged. GEM Feature and Functions The GEM controls the following features: ^ Wipers/washers (front/rear). ^ Warning chimes. ^ Battery saver. ^ Illuminated entry and courtesy lamps. ^ Driver power window. ^ Accessory delay. ^ 4-wheel drive. GEM Diagnostics The Generic Electronic Module (GEM) diagnostics are accessible with the New Generation STAR (NGS) tester and the Service Bay Diagnostic System (SBDS). The GEM constantly monitors its subsystems for concerns. If a concern is found in one of the subsystems, the GEM will record the concern in the form of a Diagnostic Trouble Code (DTC). There are three areas of diagnostic information useful when diagnosing the GEM. ^ DTCs - A record of past or present system problems. ^ PIDs - the present state of an input or output. ^ Active Commands - Gives the ability to turn on GEM outputs without activating the inputs normally associated with the function. Ignition Switch Positions The position of the ignition switch is very important to proper Generic Electronic Module (GEM) operation. Often times, erratic or unexpected operation can be traced to problems on these GEM inputs. The following is a brief description of five ignition switch positions. Run When the ignition switch is in this position, battery voltage should be present at the GEM RUN and RUN/ACC input terminals. Accessory (ACC) When the ignition switch is in this position, battery voltage should be present at the GEM RUN/ACC input terminal only. Start When the ignition switch is in this position, battery voltage should he present at the GEM start/clutch depressed input. Off and Lock The GEM does not have an OFF or LOCK Switch State input. The GEM will assume the OFF or LOCK position when there are no RUN, Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Page 10707 ACC, or START signals present. Wiper/Washer Control and Interval Timer Front Wipers There are four modes of operation for the front wipers: speed dependent interval, slow, fast, and wash. These modes are only active with the ignition switch in the RUN or ACC position. Speed dependent wipers compensate for the extra moisture that accumulates on the windshield at higher speeds. At higher speeds, the speed dependent feature shortens the delay between wipes when using the variable interval wiper feature. Delays will automatically adjust at speeds between 16 and 105 kph (10 and 65 mph). Rear Wiper There are two modes of operation for the rear wipers, internal and wash. These modes are only active with the ignition switch in the RUN or ACC positions and both the liftgate and liftgate glass are closed. Chime Warning There are five warning chimes and lamps the Generic Electronic Module (GEM) controls: Headlights operating without the ignition ON (chime only), door ajar (chime and lamp), key in the ignition (chime only), driver seat belt warning (chime and lamp), and low washer fluid warning (chime and lamp). Battery Saver The battery saver feature removes extended interior lamp power drains from the battery. The Generic Electronic Module (GEM) will keep power available for all interior lights and under hood lamp circuits for 40 minutes after the ignition switch is turned OFF. The battery saver timer is reset by unlocking doors with remote entry key fob, activating a door ajar switch, or changing the ignition to RUN or ACC position. If asleep, the GEM will wake-up when: ^ Any door becomes ajar or is closed. ^ The key is inserted or removed. ^ The ignition switch is turned to ACC or RUN. ^ The doors are unlocked with the remote entry key fob. Courtesy Lamps/Illuminated Entry The Generic Electronic Module (GEM) illuminates the interior courtesy lamps when any door is ajar. The GEM also provides illuminated entry when the unlock button is used to unlock the vehicle. All interior courtesy lamps are turned OFF when any of the following occurs: ^ Twenty-five seconds have elapsed since the illuminated entry feature was activated and no door is ajar. ^ The ignition switch is turned to RUN and no door is ajar. ^ Vehicle speed is over 15 mph (a new ajar signal will turn on courtesy lamps only if the vehicle speed is less than 10 mph). ^ A power door lock command is received from the remote entry key fob and no door is ajar. Running Board Lamps The GEM illuminates the running board lamps when the interior lamps are activated and the ignition switch is not in the RUN position. Delayed Accessory (GEM only) The delayed accessory feature provides power to the power windows for ten minutes after the ignition switch is moved from the RUN to OFF position. If during this ten-minute period either front door is opened, the delayed accessory relay will be de-energized. One-Touch Window The power switch for the driver window control has two detents for the down window control. With the ignition switch in RUN or ACC, pressing the first detent (normal mode) allows manual down window control; pressing harder to the second detent (auto) will cause the driver window to automatically move to the full down position. Pressing either the up or down window switch will cancel an auto mode operation in progress. Transfer Case (Four Wheel Drive-GEM Only) This vehicle is equipped with Automatic 4-Wheel Drive (A4WD). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Flow of Diagnosis General Module: Flow of Diagnosis 1. Verify the customer's concern by operating the system in question. 2. Visually inspect for obvious signs of mechanical and electrical damage. Mechanical ^ Switch(es). Electrical ^ Fuse(s). ^ Circuit(s). ^ Damaged wiring harness(es). ^ Loose or damaged wires or connectors. 3. If the concern is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10710 General Module: Initial Inspection and Diagnostic Overview 1. Verify the customer's concern by operating the system in question. 2. Visually inspect for obvious signs of mechanical and electrical damage. Mechanical ^ Switch(es). Electrical ^ Fuse(s). ^ Circuit(s). ^ Damaged wiring harness(es). ^ Loose or damaged wires or connectors. 3. If the concern is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10711 General Module: Diagnostic Trouble Code Descriptions Part 1 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10712 Part 2 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10713 Part 3 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10714 Part 4 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10715 Part 5 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10716 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10717 General Module: Pinpoint Tests Pinpoint Test Icons Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. A: Cannot Communicate With the GEM Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10718 A1-A2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10719 A3-A4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10720 A5-A6 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10721 A7-A8 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Page 10722 General Module: Service and Repair REMOVAL 1. Disconnect the positive or both battery cables. 2. Remove the cover from the instrument panel fuse junction panel. 3. Remove the lower instrument panel steering column cover. 1. Remove the six lower instrument panel steering column cover bolts. 2. Remove the lower instrument panel steering column cover. 4. Remove the two (A) bulkhead electrical connectors from the (B) instrument panel fuse junction panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Page 10723 5. Remove the two (A) instrument panel fuse junction panel bolts and remove the two (B) interior fuse junction panel nuts. 6. Disconnect the three (A) GEM electrical connectors from the (B) GEM. 7. Remove the three GEM screws and the GEM. INSTALLATION 1. To install, reverse the removal procedure. Check for proper operation. 2. Install the lower instrument panel steering column cover. ^ Position the lower instrument panel steering column cover. ^ Install the six screws. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Page 10724 General Module: Tools and Equipment Special Service Tool(s) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Specifications Amplifier: Specifications Radio Amplifier Screws ....................................................................................................................... .............................................. 2-3 Nm (17-26 In Lb) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Amplifier Amplifier: Diagrams Amplifier Amplifier (C263) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Amplifier > Page 10731 Amplifier (C264) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Amplifier > Page 10732 Amplifier Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Amplifier > Page 10733 Amplifier: Diagrams Subwoofer Amplifier Subwoofer Amplifier (442) Subwoofer Amplifier (C443) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Page 10734 Amplifier: Service and Repair REMOVAL NOTE: The climate control head has a top flange that extends behind the radio. The radio must be removed prior to removal of the climate control head. 1. Remove the radio chassis. 2. Position the climate control head aside. 1. Remove the four climate control head screws. 2. Pull out the climate control head and position aside. 3. If equipped, remove the instrument panel floor duct panel. ^ Remove the two push clips and release the one expander clip. 4. If equipped, remove the center console assembly. 5. Remove the radio amplifier. 1. Remove the three radio amplifier screws. 2. Disconnect the two radio amplifier electrical connectors. 3. Remove the radio amplifier. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Page 10735 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Specifications CD Changer: Specifications CD Bracket Screws ............................................................................................................................. ......................................... 1.2-1.8 Nm (11-16 In Lb) CD Changer Compartment Trim Panel Screws .................................................................................................................................. 2-3 Nm (17-26 In Lb) CD Changer Screws .................................................................................................................. ................................................... 1.2-1.8 Nm (11-16 In Lb) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Specifications > Page 10740 Compact Disc Changer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Specifications > Page 10741 CD Changer: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the mat at bottom of console bin and compact disc player compartment trim panel screws. ^ To ease removal of trim panel pull front edge back and lift out. 3. Remove the CD bracket screws and pull out CD changer and bracket. 4. Disconnect the electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Specifications > Page 10742 5. Remove the CD changer screws. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers Radio/Stereo Noise Filter: Customer Interest Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 10752 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 10753 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 10754 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 10755 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 10756 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 10757 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 10758 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers Radio/Stereo Noise Filter: All Technical Service Bulletins Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 10764 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 10765 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 10766 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 10767 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 10768 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 10769 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 10770 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Page 10771 Radio/Stereo Noise Filter: Specifications Radio Frequency Interference Suppression Bond To Bulkhead Screw ................................................................................................................................... ................................. 2.1-2.9 Nm (8.7-25.8 In Lb) Engine Nut ............................................................ ............................................................................................................. 8.9-12.1 Nm (79.4-107 In Lb) Floorpan Screws .................................................................................................................................. ..................................... 4.5-6.3 Nm (40-56 In Lb) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Page 10772 Radio/Stereo Noise Filter: Description and Operation The radio suppression equipment reduces interference transmitted through the radio speakers by the engine ignition and electrical systems. when replacing any radio suppression equipment components, make sure that a good contact is made at all connections. Remove any paint or dirt from between a component and its ground. Tighten all connectors and screws securely. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Specifications Remote Control: Specifications Rear Integrated Control Panel Screws .......................................................................................................................................... 1.2-1.8 Nm (11-16 In Lb) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Specifications > Page 10776 Remote Control: Description and Operation The audio controls of the rear integrated control panel allow the rear passengers to control volume, station, AM/FM band, memory presets, and speaker or headphone selection. The mini-headphone jacks are also located on the panel. The rear integrated control panel is located at the rear of the center console. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Specifications > Page 10777 Remote Control: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the screws and the console glove compartment door and hinge assembly. 3. Disconnect the console rear panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Specifications > Page 10778 1. Remove the screws. 2. Disengage the clips. 4. Remove the rear integrated control panel. 1. If equipped, disconnect the floor/panel control cable at the control head. 2. Disconnect the power point electrical connector. 3. If equipped, disconnect the blower motor control electrical connector. 4. Disconnect the radio control electrical connector. 5. Remove the rear integrated control panel screws. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Specifications > Page 10779 1. To install, reverse the removal procedure. NOTE: when the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers Speaker: Customer Interest Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 10788 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 10789 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 10790 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 10791 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 10792 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 10793 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 10794 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers Speaker: All Technical Service Bulletins Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 10800 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 10801 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 10802 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 10803 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 10804 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 10805 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 10806 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Page 10807 Speaker: Specifications Radio Speaker Screws ............................................................................................................................................................ 1.2-1.8 Nm (10.7-16.1 In Lb) Subwoofer Enclosure Screws ................................................................................................................................................. 5.2-7.2 Nm (46.4-64.2 In Lb) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Page 10808 Speaker: Description and Operation All vehicles are equipped with two radio speakers in the front doors and two radio speakers in the rear doors. On all vehicles: ^ The rear radio speakers are located behind the rear door trim panel. ^ The front radio speakers are located behind the front door trim panel. ^ The subwoofer (if equipped) is located behind the RH quarter trim panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Service and Repair Tape Player: Service and Repair Cleaning Tape Player For best performance, it is recommended that the tape player be cleaned once for every 10 to 12 hours of playing time. The tape player should be cleaned using a Ford tape player cleaning cartridge, available at your Ford or Lincoln-Mercury Dealer. The use of other cleaning products is not recommended, as these products could cause damage to the player or cassette tapes. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Accessory Delay Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 10817 Junction Box Fuse/Relay Panel (Part 1 Of 2) The Accessory Delay Relay is located in the junction box fuse/relay panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Specifications Alarm Module: Specifications Passive Anti-Theft System Module Screws ............................................................................................................................... 4.5-6.3 Nm (41-56.2 In Lb) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Anti-Theft Transceiver Module Alarm Module: Locations Anti-Theft Transceiver Module Instrument Panel View The Anti Theft-Transceiver Module is located behind the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Anti-Theft Transceiver Module > Page 10823 Alarm Module: Locations Passive Anti-Theft System Module Body View The Passive Anti-Theft System Module is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Anti-Theft Transceiver Module > Page 10824 Alarm Module: Locations Remote Anti-Theft Personality Module Body Views Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Anti-Theft Transceiver Module > Page 10825 The Remote Anti-Theft Personality Module is located behind left side of instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Controller Module Passive Anti-Theft System Control Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Controller Module > Page 10828 Anti-Theft Transceiver Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Controller Module > Page 10829 Alarm Module: Diagrams Remote Anti-Theft Personality Module Remote Anti-Theft Personality Module (C257) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Controller Module > Page 10830 Remote Anti-Theft Personality Module (C256) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 10831 Alarm Module: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the PATS module. 1. Disconnect the electrical connector. 2. Remove the two screws. 3. Remove the PATS module. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Specifications General Module: Specifications GEM Screws ........................................................................................................................................ .......................................... 0.9-1.3 Nm (8-12 In Lb) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Specifications > Page 10835 General Module: Locations Instrument Panel View The Generic Electronic Module is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions General Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10838 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10839 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10840 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10841 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10842 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10843 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10844 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10845 General Module: Connector Views Generic Electronic Module (C239) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10846 Generic Electronic Module (C267) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10847 Generic Electronic Module (C240 ) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10848 Generic Electronic Module (C241) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10849 General Module: Electrical Diagrams Generic Electronic Module (Part 1 Of 5) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10850 Generic Electronic Module (Part 2 Of 5) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10851 Generic Electronic Module (Part 3 Of 5) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10852 Generic Electronic Module (Part 4 Of 5) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10853 Generic Electronic Module (Part 5 Of 5) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Page 10854 General Module: Description and Operation GEM Circuit Protection Short Circuit/Battery Voltage The Generic Electronic Module (GEM) outputs are designed to withstand continuous exposure to a short circuit to ground or battery voltage without being damaged. GEM Feature and Functions The GEM controls the following features: ^ Wipers/washers (front/rear). ^ Warning chimes. ^ Battery saver. ^ Illuminated entry and courtesy lamps. ^ Driver power window. ^ Accessory delay. ^ 4-wheel drive. GEM Diagnostics The Generic Electronic Module (GEM) diagnostics are accessible with the New Generation STAR (NGS) tester and the Service Bay Diagnostic System (SBDS). The GEM constantly monitors its subsystems for concerns. If a concern is found in one of the subsystems, the GEM will record the concern in the form of a Diagnostic Trouble Code (DTC). There are three areas of diagnostic information useful when diagnosing the GEM. ^ DTCs - A record of past or present system problems. ^ PIDs - the present state of an input or output. ^ Active Commands - Gives the ability to turn on GEM outputs without activating the inputs normally associated with the function. Ignition Switch Positions The position of the ignition switch is very important to proper Generic Electronic Module (GEM) operation. Often times, erratic or unexpected operation can be traced to problems on these GEM inputs. The following is a brief description of five ignition switch positions. Run When the ignition switch is in this position, battery voltage should be present at the GEM RUN and RUN/ACC input terminals. Accessory (ACC) When the ignition switch is in this position, battery voltage should be present at the GEM RUN/ACC input terminal only. Start When the ignition switch is in this position, battery voltage should he present at the GEM start/clutch depressed input. Off and Lock The GEM does not have an OFF or LOCK Switch State input. The GEM will assume the OFF or LOCK position when there are no RUN, Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Page 10855 ACC, or START signals present. Wiper/Washer Control and Interval Timer Front Wipers There are four modes of operation for the front wipers: speed dependent interval, slow, fast, and wash. These modes are only active with the ignition switch in the RUN or ACC position. Speed dependent wipers compensate for the extra moisture that accumulates on the windshield at higher speeds. At higher speeds, the speed dependent feature shortens the delay between wipes when using the variable interval wiper feature. Delays will automatically adjust at speeds between 16 and 105 kph (10 and 65 mph). Rear Wiper There are two modes of operation for the rear wipers, internal and wash. These modes are only active with the ignition switch in the RUN or ACC positions and both the liftgate and liftgate glass are closed. Chime Warning There are five warning chimes and lamps the Generic Electronic Module (GEM) controls: Headlights operating without the ignition ON (chime only), door ajar (chime and lamp), key in the ignition (chime only), driver seat belt warning (chime and lamp), and low washer fluid warning (chime and lamp). Battery Saver The battery saver feature removes extended interior lamp power drains from the battery. The Generic Electronic Module (GEM) will keep power available for all interior lights and under hood lamp circuits for 40 minutes after the ignition switch is turned OFF. The battery saver timer is reset by unlocking doors with remote entry key fob, activating a door ajar switch, or changing the ignition to RUN or ACC position. If asleep, the GEM will wake-up when: ^ Any door becomes ajar or is closed. ^ The key is inserted or removed. ^ The ignition switch is turned to ACC or RUN. ^ The doors are unlocked with the remote entry key fob. Courtesy Lamps/Illuminated Entry The Generic Electronic Module (GEM) illuminates the interior courtesy lamps when any door is ajar. The GEM also provides illuminated entry when the unlock button is used to unlock the vehicle. All interior courtesy lamps are turned OFF when any of the following occurs: ^ Twenty-five seconds have elapsed since the illuminated entry feature was activated and no door is ajar. ^ The ignition switch is turned to RUN and no door is ajar. ^ Vehicle speed is over 15 mph (a new ajar signal will turn on courtesy lamps only if the vehicle speed is less than 10 mph). ^ A power door lock command is received from the remote entry key fob and no door is ajar. Running Board Lamps The GEM illuminates the running board lamps when the interior lamps are activated and the ignition switch is not in the RUN position. Delayed Accessory (GEM only) The delayed accessory feature provides power to the power windows for ten minutes after the ignition switch is moved from the RUN to OFF position. If during this ten-minute period either front door is opened, the delayed accessory relay will be de-energized. One-Touch Window The power switch for the driver window control has two detents for the down window control. With the ignition switch in RUN or ACC, pressing the first detent (normal mode) allows manual down window control; pressing harder to the second detent (auto) will cause the driver window to automatically move to the full down position. Pressing either the up or down window switch will cancel an auto mode operation in progress. Transfer Case (Four Wheel Drive-GEM Only) This vehicle is equipped with Automatic 4-Wheel Drive (A4WD). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Flow of Diagnosis General Module: Flow of Diagnosis 1. Verify the customer's concern by operating the system in question. 2. Visually inspect for obvious signs of mechanical and electrical damage. Mechanical ^ Switch(es). Electrical ^ Fuse(s). ^ Circuit(s). ^ Damaged wiring harness(es). ^ Loose or damaged wires or connectors. 3. If the concern is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10858 General Module: Initial Inspection and Diagnostic Overview 1. Verify the customer's concern by operating the system in question. 2. Visually inspect for obvious signs of mechanical and electrical damage. Mechanical ^ Switch(es). Electrical ^ Fuse(s). ^ Circuit(s). ^ Damaged wiring harness(es). ^ Loose or damaged wires or connectors. 3. If the concern is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10859 General Module: Diagnostic Trouble Code Descriptions Part 1 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10860 Part 2 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10861 Part 3 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10862 Part 4 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10863 Part 5 Of 5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10864 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10865 General Module: Pinpoint Tests Pinpoint Test Icons Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. A: Cannot Communicate With the GEM Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10866 A1-A2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10867 A3-A4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10868 A5-A6 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10869 A7-A8 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Page 10870 General Module: Service and Repair REMOVAL 1. Disconnect the positive or both battery cables. 2. Remove the cover from the instrument panel fuse junction panel. 3. Remove the lower instrument panel steering column cover. 1. Remove the six lower instrument panel steering column cover bolts. 2. Remove the lower instrument panel steering column cover. 4. Remove the two (A) bulkhead electrical connectors from the (B) instrument panel fuse junction panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Page 10871 5. Remove the two (A) instrument panel fuse junction panel bolts and remove the two (B) interior fuse junction panel nuts. 6. Disconnect the three (A) GEM electrical connectors from the (B) GEM. 7. Remove the three GEM screws and the GEM. INSTALLATION 1. To install, reverse the removal procedure. Check for proper operation. 2. Install the lower instrument panel steering column cover. ^ Position the lower instrument panel steering column cover. ^ Install the six screws. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Testing and Inspection > Page 10872 General Module: Tools and Equipment Special Service Tool(s) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Specifications Keyless Entry Module: Specifications RAP Module Nuts ................................................................................................................................ ...................................................... 7 Nm (62.4 in lb) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Specifications > Page 10876 Keyless Entry Module: Locations Body Views Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Specifications > Page 10877 The Remote Anti-Theft Personality Module is located behind left side of instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Specifications > Page 10878 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect the C257 and C256 Remote Anti-theft Personality (RAP) module electrical connectors. 2. Disconnect the antenna connector. 3. Remove the RAP module nuts and the RAP module. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Service and Repair Lock Cylinder Switch: Service and Repair REMOVAL NOTE: In the images, the steering wheel is removed for clarity. 1. If equipped, twist the tilt wheel handle and shank and remove. 2. Remove the lower steering column shroud. 1. Remove the three lower steering column shroud screws. 2. Remove the lower steering column shroud. 3. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to RUN position. 2. Push the (A) ignition switch lock cylinder release tab with a punch while pulling out the (B) ignition switch lock cylinder. 4. Carefully pry to release the four clips and remove the steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Service and Repair > Page 10883 5. Remove the upper steering column shroud. 6. Remove the upper instrument panel steering column cover. 7. Remove the ignition lock anti-theft switch. 1. Disconnect the electrical connector. 2. Remove the ignition lock anti-theft switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10889 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10890 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10891 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10892 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10893 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10894 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10895 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10896 Trailer Connector: Electrical Diagrams Trailer/Camper Adapter (Part 1 Of 3) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10897 Trailer/Camper Adapter (Part 2 Of 3) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10898 Trailer/Camper Adapter (Part 3 Of 3) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement Technical Service Bulletin # 00S05 Date: 000501 Recall - Trailer Hitch Hardware Replacement 00S05 SAFETY RECALL All 1997-2000 Model Year Expedition and Navigator with Trailer Hitch Package - Hitch Attachment ^ Original - May, 2000 Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter Customer Notification Letter ^ Supplement # 1 - May, 2000 Aftermarket Hitch Kits and Existing Dealer Stock Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 10907 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 10908 Attachment I OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. NOTE: Navigator owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Lincoln owners, review Attachment IV to familiarize yourself with this special handling procedure. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instruction on page two of Attachment IV. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Only Navigator owners are eligible for rental cars under the provisions of the "Lincoln Commitment Special Handling Procedure" (refer to Attachment IV). Attachment II Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 10909 LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Parts wilt not be direct shipped for this recall. Order your parts requirement through normal order processing channels as shown. MATERIAL ALLOWANCE A material allowance of $5.25 per vehicle is being given to purchase an underbody coating (Super Seal or equivalent product). Claim this allowance by entering the information shown. SPECIAL ORDER INFORMATION DOR/COR number 50161 identifies parts ordered for this campaign through the Recall Hotline (800-325-5621), for the first 30 days. DEALER PRICE For latest prices, refer to: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III AFFECTED VEHICLES: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 10910 CERTAIN 1997 THROUGH 2000 MODEL YEAR EXPEDITION AND NAVIGATOR EQUIPPED WITH FACTORY INSTALLED TRAILER HITCH OVERVIEW This procedure outlines hitch assembly removal, cleaning and reinstallation using updated attaching hardware. NOTE: REMOVING THE FRAME WAX AS OUTLINED IN STEP 5 IS CRITICAL TO THE OVERALL ROBUSTNESS OF THIS REPAIR. SERVICE PROCEDURE 1. Turn off the air suspension switch, then raise and support the vehicle on a hoist. 2. Remove the hitch electrical connector bracket from the hitch assembly. 3. Position two (2) jack stands to support the hitch assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 10911 4. Remove all bolts and nut plates attaching the hitch to the frame, then remove the hitch assembly from the vehicle. See Figures 1 and 2. 5. Using Brake Metal Parts Cleaner (F6AZ-2C410-AB) or equivalent obtained locally, remove the frame wax from all areas where there is hitch- or nut plate-to-frame contact. This includes: ^ the inside areas of the hitch ^ the inside and outside areas of the frame web. ^ the upper and lower areas of the frame flanges. CAUTION To avoid cross threading the bolts into the nut plates, start each bolt by hand and be sure it is threading properly into the nut plate. CAUTION Do not final tighten any bolts until all have been installed. Be sure to tighten the horizontal bolts first (Step 7) before tightening the vertical bolts (Step 8). 6. Reposition the hitch on the jack stands and install the new bolts and new nut plates. Only tighten the bolts snug at this time. 7. Tighten the horizontal attaching bolts to 175 Nm (129 lb-ft). 8. Tighten the vertical attaching bolts to 175 Nm (129 lb-ft). 9. Remove the jack stands. 10. Install the hitch electrical connector bracket. For 7-pin connectors, tighten the bolt to 48 Nm (35 lb-ft). For 4-pin connectors, tighten the bolt to 63 Nm (46 lb-ft). 11. Apply a coat of commercially available underbody anti-corrosion compound meeting Ford specification ESR-M7C54-A to the hitch attachment area ensuring adequate coverage. 12. Lower the vehicle and turn on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 10912 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 10913 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 10914 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 10915 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 10916 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 10917 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 10918 Supplement # 1 - Attachment I OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT (I )Immediately contact any affected owner whose name is not on the list Give the owner a copy of the Owner Letter and schedule a service date. This contact includes owners who have purchased aftermarket hitch kit # F75Z-17D826-AE. NOTE: Navigator owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Lincoln owners, review Attachment IV to familiarize yourself with this special handling procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 10919 REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instructions on page two of Attachment IV. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Only Navigator owners are eligible for rental cars under the provisions of the "Lincoln Commitment Special Handling Procedure" (refer to Attachment IV). Supplement # 1 - Attachment II LABOR ALLOWANCES PARTS REQUIREMENTS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 10920 Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channels as shown above. MATERIAL ALLOWANCE A material allowance of $5.25 per vehicle is being given to purchase an underbody coating (Super Seal or equivalent product). Claim this allowance by entering the information above: SPECIAL ORDER INFORMATION DOR/COR number 50161 identifies parts ordered for this campaign through the Recall Hotline (800-325-5621), for the first 30 days. (I )REWORK OF EXISTING DEALER STOCK Call the Recall Hotline at 1-800-325-5621,to obtain instructions for reworking existing stock of Trailer Hitch Kits (part # F75Z-17D826-AE). NOTE: The Recall Hotline will provide new hardware and kit installation instructions.When you rework dealer stock, please make sure these revised instructions (with new torque specifications) are included in the kit. DEALER PRICE For latest prices, refer to: ^ DOESII ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Supplement # 1 - Attachment III HITCH ATTACHING FASTENER REPLACEMENT AFFECTED VEHICLES: CERTAIN 1997 THROUGH 2000 MODEL YEAR EXPEDITION AND NAVIGATOR EQUIPPED WITH FACTORY INSTALLED TRAILER HITCH OVERVIEW This procedure outlines hitch assembly removal, cleaning and reinstallation using updated attaching hardware. NOTE: REMOVING THE FRAME WAX AS OUTLINED IN STEP 5 IS CRITICAL TO THE OVERALL ROBUSTNESS OF THIS REPAIR. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 10921 SERVICE PROCEDURE 1. Turn off the air suspension switch, then raise and support the vehicle on a hoist. 2. Remove the hitch electrical connector bracket from the hitch assembly. 3. Position two (2) jack stands to support the hitch assembly. 4. Remove all bolts and nut plates attaching the hitch to the frame, then remove the hitch assembly from the vehicle. See Figures 1 and 2. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 10922 5. Using Brake Metal Parts Cleaner (F6AZ-2C410-AB) or equivalent obtained locally, remove the frame wax from all areas where there is hitch- or nut plate-to-frame contact. This includes: ^ the inside areas of the hitch. ^ the inside and outside areas of the frame web. ^ the upper and lower areas of the frame flanges. CAUTION To avoid cross threading the bolts into the nut plates, start each bolt by hand and be sure it is threading properly into the nut plate. CAUTION Do not final tighten any bolts until all have been installed. Be sure to tighten the horizontal bolts first (Step 7) before tightening the vertical bolts (Step 8). 6. Reposition the hitch on the jack stands and install the new bolts and new nut plates. Only tighten the bolts snug at this time. 7. Tighten the horizontal attaching bolts to 175 Nm (129 lb-ft). 8. Tighten the vertical attaching bolts to 175 Nm (129 lb-ft). 9. Remove the jack stands. 10. Install the hitch electrical connector bracket. For 7-pin connectors, tighten the bolt to 48 Nm (35 lb-ft). For 4-pin connectors, tighten the bolt to 63 Nm (46 lb-ft). 11. Apply a coat of commercially available underbody anti-corrosion compound meeting Ford specification ESR-M7C54-A to the hitch attachment area ensuring adequate coverage. 12. Lower the vehicle and turn on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 10923 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 10924 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 10925 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 10926 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > NHTSA00V073000 > Mar > 00 > Recall 00V073000: Trailer Hitch Attaching Bolts Loose Trailer Hitch: Recalls Recall 00V073000: Trailer Hitch Attaching Bolts Loose Vehicle Description: Multi-purpose vehicles. The trailer hitch assembly to the frame attaching bolts could lose the clamp load. The trailer hitch could then separate from the vehicle. Dealers will replace the trailer hitch mounting bolts and nut plates. Owner notification began May 15, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1997 FORD TRUCK EXPEDITION 1997 LINCOLN TRUCK NAVIGATOR 1998 FORD TRUCK EXPEDITION 1998 LINCOLN TRUCK NAVIGATOR 1999 FORD TRUCK EXPEDITION 1999 LINCOLN TRUCK NAVIGATOR 2000 FORD TRUCK EXPEDITION 2000 LINCOLN TRUCK NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement Technical Service Bulletin # 00S05 Date: 000501 Recall - Trailer Hitch Hardware Replacement 00S05 SAFETY RECALL All 1997-2000 Model Year Expedition and Navigator with Trailer Hitch Package - Hitch Attachment ^ Original - May, 2000 Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter Customer Notification Letter ^ Supplement # 1 - May, 2000 Aftermarket Hitch Kits and Existing Dealer Stock Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 10936 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 10937 Attachment I OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. NOTE: Navigator owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Lincoln owners, review Attachment IV to familiarize yourself with this special handling procedure. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instruction on page two of Attachment IV. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Only Navigator owners are eligible for rental cars under the provisions of the "Lincoln Commitment Special Handling Procedure" (refer to Attachment IV). Attachment II Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 10938 LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Parts wilt not be direct shipped for this recall. Order your parts requirement through normal order processing channels as shown. MATERIAL ALLOWANCE A material allowance of $5.25 per vehicle is being given to purchase an underbody coating (Super Seal or equivalent product). Claim this allowance by entering the information shown. SPECIAL ORDER INFORMATION DOR/COR number 50161 identifies parts ordered for this campaign through the Recall Hotline (800-325-5621), for the first 30 days. DEALER PRICE For latest prices, refer to: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III AFFECTED VEHICLES: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 10939 CERTAIN 1997 THROUGH 2000 MODEL YEAR EXPEDITION AND NAVIGATOR EQUIPPED WITH FACTORY INSTALLED TRAILER HITCH OVERVIEW This procedure outlines hitch assembly removal, cleaning and reinstallation using updated attaching hardware. NOTE: REMOVING THE FRAME WAX AS OUTLINED IN STEP 5 IS CRITICAL TO THE OVERALL ROBUSTNESS OF THIS REPAIR. SERVICE PROCEDURE 1. Turn off the air suspension switch, then raise and support the vehicle on a hoist. 2. Remove the hitch electrical connector bracket from the hitch assembly. 3. Position two (2) jack stands to support the hitch assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 10940 4. Remove all bolts and nut plates attaching the hitch to the frame, then remove the hitch assembly from the vehicle. See Figures 1 and 2. 5. Using Brake Metal Parts Cleaner (F6AZ-2C410-AB) or equivalent obtained locally, remove the frame wax from all areas where there is hitch- or nut plate-to-frame contact. This includes: ^ the inside areas of the hitch ^ the inside and outside areas of the frame web. ^ the upper and lower areas of the frame flanges. CAUTION To avoid cross threading the bolts into the nut plates, start each bolt by hand and be sure it is threading properly into the nut plate. CAUTION Do not final tighten any bolts until all have been installed. Be sure to tighten the horizontal bolts first (Step 7) before tightening the vertical bolts (Step 8). 6. Reposition the hitch on the jack stands and install the new bolts and new nut plates. Only tighten the bolts snug at this time. 7. Tighten the horizontal attaching bolts to 175 Nm (129 lb-ft). 8. Tighten the vertical attaching bolts to 175 Nm (129 lb-ft). 9. Remove the jack stands. 10. Install the hitch electrical connector bracket. For 7-pin connectors, tighten the bolt to 48 Nm (35 lb-ft). For 4-pin connectors, tighten the bolt to 63 Nm (46 lb-ft). 11. Apply a coat of commercially available underbody anti-corrosion compound meeting Ford specification ESR-M7C54-A to the hitch attachment area ensuring adequate coverage. 12. Lower the vehicle and turn on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 10941 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 10942 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 10943 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 10944 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 10945 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 10946 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 10947 Supplement # 1 - Attachment I OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT (I )Immediately contact any affected owner whose name is not on the list Give the owner a copy of the Owner Letter and schedule a service date. This contact includes owners who have purchased aftermarket hitch kit # F75Z-17D826-AE. NOTE: Navigator owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Lincoln owners, review Attachment IV to familiarize yourself with this special handling procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 10948 REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instructions on page two of Attachment IV. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Only Navigator owners are eligible for rental cars under the provisions of the "Lincoln Commitment Special Handling Procedure" (refer to Attachment IV). Supplement # 1 - Attachment II LABOR ALLOWANCES PARTS REQUIREMENTS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 10949 Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channels as shown above. MATERIAL ALLOWANCE A material allowance of $5.25 per vehicle is being given to purchase an underbody coating (Super Seal or equivalent product). Claim this allowance by entering the information above: SPECIAL ORDER INFORMATION DOR/COR number 50161 identifies parts ordered for this campaign through the Recall Hotline (800-325-5621), for the first 30 days. (I )REWORK OF EXISTING DEALER STOCK Call the Recall Hotline at 1-800-325-5621,to obtain instructions for reworking existing stock of Trailer Hitch Kits (part # F75Z-17D826-AE). NOTE: The Recall Hotline will provide new hardware and kit installation instructions.When you rework dealer stock, please make sure these revised instructions (with new torque specifications) are included in the kit. DEALER PRICE For latest prices, refer to: ^ DOESII ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Supplement # 1 - Attachment III HITCH ATTACHING FASTENER REPLACEMENT AFFECTED VEHICLES: CERTAIN 1997 THROUGH 2000 MODEL YEAR EXPEDITION AND NAVIGATOR EQUIPPED WITH FACTORY INSTALLED TRAILER HITCH OVERVIEW This procedure outlines hitch assembly removal, cleaning and reinstallation using updated attaching hardware. NOTE: REMOVING THE FRAME WAX AS OUTLINED IN STEP 5 IS CRITICAL TO THE OVERALL ROBUSTNESS OF THIS REPAIR. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 10950 SERVICE PROCEDURE 1. Turn off the air suspension switch, then raise and support the vehicle on a hoist. 2. Remove the hitch electrical connector bracket from the hitch assembly. 3. Position two (2) jack stands to support the hitch assembly. 4. Remove all bolts and nut plates attaching the hitch to the frame, then remove the hitch assembly from the vehicle. See Figures 1 and 2. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 10951 5. Using Brake Metal Parts Cleaner (F6AZ-2C410-AB) or equivalent obtained locally, remove the frame wax from all areas where there is hitch- or nut plate-to-frame contact. This includes: ^ the inside areas of the hitch. ^ the inside and outside areas of the frame web. ^ the upper and lower areas of the frame flanges. CAUTION To avoid cross threading the bolts into the nut plates, start each bolt by hand and be sure it is threading properly into the nut plate. CAUTION Do not final tighten any bolts until all have been installed. Be sure to tighten the horizontal bolts first (Step 7) before tightening the vertical bolts (Step 8). 6. Reposition the hitch on the jack stands and install the new bolts and new nut plates. Only tighten the bolts snug at this time. 7. Tighten the horizontal attaching bolts to 175 Nm (129 lb-ft). 8. Tighten the vertical attaching bolts to 175 Nm (129 lb-ft). 9. Remove the jack stands. 10. Install the hitch electrical connector bracket. For 7-pin connectors, tighten the bolt to 48 Nm (35 lb-ft). For 4-pin connectors, tighten the bolt to 63 Nm (46 lb-ft). 11. Apply a coat of commercially available underbody anti-corrosion compound meeting Ford specification ESR-M7C54-A to the hitch attachment area ensuring adequate coverage. 12. Lower the vehicle and turn on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 10952 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 10953 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 10954 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall Trailer Hitch Hardware Replacement > Page 10955 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > NHTSA00V073000 > Mar > 00 > Recall 00V073000: Trailer Hitch Attaching Bolts Loose Trailer Hitch: All Technical Service Bulletins Recall 00V073000: Trailer Hitch Attaching Bolts Loose Vehicle Description: Multi-purpose vehicles. The trailer hitch assembly to the frame attaching bolts could lose the clamp load. The trailer hitch could then separate from the vehicle. Dealers will replace the trailer hitch mounting bolts and nut plates. Owner notification began May 15, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1997 FORD TRUCK EXPEDITION 1997 LINCOLN TRUCK NAVIGATOR 1998 FORD TRUCK EXPEDITION 1998 LINCOLN TRUCK NAVIGATOR 1999 FORD TRUCK EXPEDITION 1999 LINCOLN TRUCK NAVIGATOR 2000 FORD TRUCK EXPEDITION 2000 LINCOLN TRUCK NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis Trailer Lamps: Flow of Diagnosis Special Service Tool(s) Special Tool(s) 1. Verify the customer concern by operating the trailer towing package. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Electrical ^ Blown fuse(s) ^ Corroded/loose connector(s) ^ Loose/broken wire(s) ^ Failed bulb(s) 3. If concern is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10964 Trailer Lamps: Initial Inspection and Diagnostic Overview Special Service Tool(s) Special Tool(s) 1. Verify the customer concern by operating the trailer towing package. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Electrical ^ Blown fuse(s) ^ Corroded/loose connector(s) ^ Loose/broken wire(s) ^ Failed bulb(s) 3. If concern is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10965 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10966 Trailer Lamps: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10967 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10968 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10969 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10970 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10971 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10972 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10973 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10974 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10975 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10976 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10977 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10978 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10979 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10980 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10981 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10982 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10983 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10984 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10985 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10986 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10987 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10992 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10993 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10994 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10995 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10996 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10997 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10998 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 10999 Trailer Connector: Electrical Diagrams Trailer/Camper Adapter (Part 1 Of 3) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 11000 Trailer/Camper Adapter (Part 2 Of 3) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 11001 Trailer/Camper Adapter (Part 3 Of 3) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Locations Trip Computer: Locations Body View Overhead Trip Computer Module is located in front of overhead console. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Locations > Page 11005 Overhead Trip Computer Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Technical Service Bulletins > Customer Interest for Auxiliary Step / Running Board: > 98-13-15 > Jul > 98 > Running Boards - Too Narrow When Exiting Vehicle Auxiliary Step / Running Board: Customer Interest Running Boards - Too Narrow When Exiting Vehicle Article No. 98-13-15 07/06/98 RUNNING BOARDS - PERCEPTION OF RUNNING BOARDS BEING TOO NARROW WHEN EXITING VEHICLE - SERVICE TIP LIGHT TRUCK: 1997-98 EXPEDITION ISSUE The running boards may be too narrow for some customers when exiting the vehicle. ACTION A service kit is available to move the running board outboard 25 mm (1"). Refer to the Instruction Sheet (F85B-16450-AB) included in the kit for installation procedures. PART NUMBER PART NAME F85Z-16450-AB Running Board Service Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 108000, 190000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Technical Service Bulletins > By Symptom for Auxiliary Step / Running Board: > 98-13-15 > Jul > 98 > Running Boards - Too Narrow When Exiting Vehicle Auxiliary Step / Running Board: By Symptom Running Boards - Too Narrow When Exiting Vehicle Article No. 98-13-15 07/06/98 RUNNING BOARDS - PERCEPTION OF RUNNING BOARDS BEING TOO NARROW WHEN EXITING VEHICLE - SERVICE TIP LIGHT TRUCK: 1997-98 EXPEDITION ISSUE The running boards may be too narrow for some customers when exiting the vehicle. ACTION A service kit is available to move the running board outboard 25 mm (1"). Refer to the Instruction Sheet (F85B-16450-AB) included in the kit for installation procedures. PART NUMBER PART NAME F85Z-16450-AB Running Board Service Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 108000, 190000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Step / Running Board: > 98-13-15 > Jul > 98 > Running Boards - Too Narrow When Exiting Vehicle Auxiliary Step / Running Board: All Technical Service Bulletins Running Boards - Too Narrow When Exiting Vehicle Article No. 98-13-15 07/06/98 RUNNING BOARDS - PERCEPTION OF RUNNING BOARDS BEING TOO NARROW WHEN EXITING VEHICLE - SERVICE TIP LIGHT TRUCK: 1997-98 EXPEDITION ISSUE The running boards may be too narrow for some customers when exiting the vehicle. ACTION A service kit is available to move the running board outboard 25 mm (1"). Refer to the Instruction Sheet (F85B-16450-AB) included in the kit for installation procedures. PART NUMBER PART NAME F85Z-16450-AB Running Board Service Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 108000, 190000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Bumper > Component Information > Technical Service Bulletins > Customer Interest: > 98-1-13 > Jan > 98 > Bumper - Rust Staining Technical Service Bulletin # 98-1-13 Date: 980119 Bumper - Rust Staining Article No. 98-1-13 01/19/98 BUMPER - RUST STAIN - EDGES OF CENTER VENT AND FOG LAMP OPENINGS LIGHT TRUCK: 1990-96 BRONCO 1990-97 F-250 HD, F-350 1997 ECONOLINE, EXPLORER 1997-98 EXPEDITION, F-150, F-250 LD ISSUE: Red rust stains on the edges of the bumper center vent and fog lamp openings may appear on some vehicles. ACTION: Apply Super Seal Anti-Corrosion Compound to the affected areas of the bumper. Refer to the following Service Procedures for details. NOTE: USE A PROTECTIVE GLOVE FOR APPLYING BOTH THE CUSTOM BRIGHT METAL CLEANER (8A-19522-A) AND THE SUPER SEAL ANTI-CORROSION COMPOUND (F3AZ-19515-SA). For each of the specific vehicle procedures found in this TSB article, be sure the following 3 steps are done: 1. Clean the red rust stain from the inside and chrome surface of the bumper. 2. Paint the edge of openings and at least 25 mm (1") area around the inside of the bumper vent and fog lamp openings. 3. Spray around the top cover attachment holes/slots. PART NUMBER PART NAME F3AZ-19515-SA Super Seal Anti-Corrosion compound 8A-19522-A Custom Bright Metal cleaner OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 980113A Apply Sealer - Front 0.8 Hr. Bumper - 1997-98 Expedition/F-150-250 LD 4X4 Under 8500 Lbs GVW 980113B Apply Sealer - Front 0.5 Hr. Bumper - 1997-98 F-150-250 LD 4X2 Under 8500 Lbs GVW 980113C Apply Sealer - Rear 0.4 Hr. Bumper - 1997-98 F-150-250 LD 4X2/4X4 Under 8500 Lbs GVW 980113D Apply Sealer - Front 0.5 Hr. Bumper - 1990-97 F-250 HD/F-350/Bronco 980113E Apply Sealer - Rear 0.4 Hr. Bumper - 1990-97 F-250 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Bumper > Component Information > Technical Service Bulletins > Customer Interest: > 98-1-13 > Jan > 98 > Bumper - Rust Staining > Page 11033 HD/F-350/Bronco 980113F Apply Sealer - Rear 0.6 Hr. Bumper - 1997-98 Expedition 980113G Apply Sealer - Front 0.5 Hr. Bumper - 1997 Explorer XLT/Eddie Bauer 980113H Apply Sealer - Rear 0.5 Hr. Bumper - 1997 Explorer 9801131 Apply Sealer - Front 0.5 Hr. Bumper - 1997 Econoline DEALER CODING CONDITION BASIC PART NO. CODE 17757 68 OASIS CODES: 106000 1997-98 Expedition/F-150/250 LD 4X4 Frnt. Bumper 1997-98 EXPEDITION AND F-150/250 LD 4X4 FRONT BUMPER 1. Turn off air suspension if applicable. 2. Hoist vehicle until bumper is at working level. 3. Remove the fog lamps or fog lamp blanks. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Bumper > Component Information > Technical Service Bulletins > Customer Interest: > 98-1-13 > Jan > 98 > Bumper - Rust Staining > Page 11034 4. Mask the front face of the center at air opening and both fog lamp openings (Figure 1). 5. Disconnect fog lamp wiring and block heater wires from the bumper. 6. Disconnect the three (3) push pins for the splash guard. 7. Clean excessive dirt from inside and outside the bumper. 8. Spray the edges of the three (3) openings with Super Seal Anti-Corrosion Compound. 9. Remove the tape from the fog lamp openings so as not to get the Super Seal Anti-Corrosion Compound on the fog lamps during reinstallation. 10. Reinstall the fog lamps/fog lamp blanks. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Bumper > Component Information > Technical Service Bulletins > Customer Interest: > 98-1-13 > Jan > 98 > Bumper - Rust Staining > Page 11035 11. Plug in fog lamp wiring and push pins for the block heater connector and lower valance push pins. 12. Lower vehicle and turn on air suspension if so equipped. 13. Clean vent and fog lamp openings as needed. 1997-98 F-150/250 LD 4X2 Front Bumper 1997-98 F-150/250 LD 4X2 FRONT BUMPER 1. Turn off air suspension it applicable. 2. Hoist vehicle until bumper is at working level. 3. Clean excessive dirt from inside and outside the bumper. 4. Remove the five (5) push pins to the radiator support. 5. Spray the edges of the air intake opening and the bumper cover retainer openings and drain holes with Super Seal Anti-Corrosion Compound. 6. Reinstall the push pins and remove the tape. 7. Lower vehicle and turn on air suspension if so equipped. 8. Clean off overspray as needed. 1997-98 F-150/250 LD Rear Bumper (4X2/4X4) 1997-98 F-150/250 LD REAR BUMPER (4X2 AND 4X4) 1. Turn off air suspension if applicable. 2. Hoist vehicle until bumper is at working level. 3. Clean excessive dirt from inside and outside the bumper. 4. Spray the back of the bumper from underneath the vehicle. Make sure to spray the license plate lights, openings, and the bumper pad retaining holes with Super Seal Anti-Corrosion Compound. 5. Lower vehicle and turn on air suspension if so equipped. 6. Clean off overspray as needed. 1990-97 F-250 HD/F-350/Bronco Frnt./Rear Bumper 1990-97 F-250 HD/F-350/BRONCO - FRONT BUMPER 1. Hoist vehicle until bumper is at working level. 2. Remove the lower valance out of the way to allow access to inside of front bumper. 3. Clean excessive dirt from inside and outside the bumper. 4. Tape license plate bolt holes. 5. Spray the edge of the opening and the bolt opening area including the license plate lights bracket holes with Super Seal Anti-Corrosion Compound. 6. Reinstall lower valance. 7. Remove protective tape. 8. Lower vehicle. 9. Clean off overspray as needed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Bumper > Component Information > Technical Service Bulletins > Customer Interest: > 98-1-13 > Jan > 98 > Bumper - Rust Staining > Page 11036 1990-97 F-250 HD/F-350/BRONCO - REAR BUMPER 1. Install newspaper between the tailgate and the bumper top cover to prevent spray on the tailgate. 2. Hoist vehicle until bumper is at working level. 3. Clean excessive dirt from inside and outside the bumper. 4. Spray the back side of the bumper from underneath the vehicle. Make sure to spray the license plate light opening, and the bolt mounting areas above the bumper mounting bracket to prevent water from leaking to the front from the back side. Also spray the bumper pad retaining holes. 5. Lower vehicle. 6. Remove paper and clean off overspray as needed. 1997-98 Expedition - Rear Bumper 1997-98 EXPEDITION - REAR BUMPER 1. Turn off air suspension, if equipped. 2. Remove spare tire. 3. Hoist vehicle until bumper is at working level. 4. Clean excessive dirt from inside and outside the bumper. 5. Spray the back of the bumper from underneath the vehicle with Super Seal Anti-Corrosion Compound. 6. Lower vehicle and turn on air suspension if so equipped. 7. Reinstall spare tire. 8. Clean off overspray as needed. 1997 Explorer XLT/Eddie Bauer - Frnt. Bumper 1997 EXPLORER XLT/EDDIE BAUER - FRONT BUMPER 1. Hoist vehicle until bumper is at working level. 2. Remove the four (4) screws and two (2) push pins from the lower valance of the radiator and remove valance. 3. Tape the air intake openings in the bumper (Figure 1). Removal of the license plate bracket is not required. 4. Clean excessive dirt from inside and outside the bumper. 5. Spray the edge of the air intake opening and the bumper cover retainer openings with Super Seal Anti-Corrosion Compound. 6. Remove tape and reinstall the radiator lower valance. 7. Lower vehicle. 8. Clean off overspray as needed. 1997 Explorer - Rear Bumper 1997 EXPLORER - REAR BUMPER 1. Remove spare tire. 2. Hoist vehicle until bumper is at working level. 3. Clean excessive dirt from inside and outside the bumper. A light amount will not affect the effectiveness of the Super Seal Anti-Corrosion Compound. 4. Spray the back of the bumper with Super Seal Anti-Corrosion Compound paying close attention to the areas around the license plate lights and the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Bumper > Component Information > Technical Service Bulletins > Customer Interest: > 98-1-13 > Jan > 98 > Bumper - Rust Staining > Page 11037 top cover retaining tab openings in the bumper. These are the areas that let the back side rust bleed to the front of the bumper and cause stain. 5. Lower vehicle. 6. Reinstall spare tire. 7. Clean off overspray as needed. 1997 Econoline - Front Bumper 1997 ECONOLINE - FRONT BUMPER 1. Hoist vehicle until bumper is at working level. 2. Remove the two (2) lower valance push pins and remove valance. 3. Tape the air intake opening. 4. Clean excessive dirt from inside and outside the bumper. 5. Spray the edge of the air intake opening and the bumper cover retainer openings with Super Seal Anti-Corrosion Compound. 6. Remove tape and reinstall the lower valance push pins. 7. Lower vehicle. 8. Clean off overspray as needed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Bumper > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-15-15 > Aug > 98 > Front Suspension - Clunking Noise Stabilizer Bushing: All Technical Service Bulletins Front Suspension - Clunking Noise Article No. 98-15-15 08/03/98 ^ SUSPENSION - "CLUNKING" NOISE HEARD FROM FRONT END - VEHICLES BUILT THROUGH 4/8/98 - 4X4 ONLY ^ NOISE - "CLUNKING" HEARD FROM FRONT END - VEHICLES BUILT THROUGH 4/8/98 - 4X4 ONLY LIGHT TRUCK: 1997-98 EXPEDITION 1998 NAVIGATOR This TSB article is being republished in its entirety to clarify that this article pertains to 4X4 vehicles only. ISSUE A "clunking" noise may be heard from the front end on some vehicles. This may be caused by the front stabilizer bar contacting the frame. ACTION Replace stabilizer bar and stabilizer bar insulators with revised service parts. Refer to the 1998 Expedition/Navigator Workshop Manual, Page 204-01B-21, for details. PART NUMBER PART NAME XL1Z-5482-CA Stabilizer Bar XL1Z-5484-GA Stabilizer bar insulator (2 Required) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-10-10 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 981515A Replace Stabilizer Bar And 1.3 Hrs. Insulators DEALER CODING CONDITION BASIC PART NO. CODE 5482 33 OASIS CODES:303000, 304000, 702000, 702100, 702300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Bumper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Bumper: > 01-16-6 > Aug > 01 > Customer Interest for Bumper: > 98-1-13 > Jan > 98 > Bumper - Rust Staining Technical Service Bulletin # 98-1-13 Date: 980119 Bumper - Rust Staining Article No. 98-1-13 01/19/98 BUMPER - RUST STAIN - EDGES OF CENTER VENT AND FOG LAMP OPENINGS LIGHT TRUCK: 1990-96 BRONCO 1990-97 F-250 HD, F-350 1997 ECONOLINE, EXPLORER 1997-98 EXPEDITION, F-150, F-250 LD ISSUE: Red rust stains on the edges of the bumper center vent and fog lamp openings may appear on some vehicles. ACTION: Apply Super Seal Anti-Corrosion Compound to the affected areas of the bumper. Refer to the following Service Procedures for details. NOTE: USE A PROTECTIVE GLOVE FOR APPLYING BOTH THE CUSTOM BRIGHT METAL CLEANER (8A-19522-A) AND THE SUPER SEAL ANTI-CORROSION COMPOUND (F3AZ-19515-SA). For each of the specific vehicle procedures found in this TSB article, be sure the following 3 steps are done: 1. Clean the red rust stain from the inside and chrome surface of the bumper. 2. Paint the edge of openings and at least 25 mm (1") area around the inside of the bumper vent and fog lamp openings. 3. Spray around the top cover attachment holes/slots. PART NUMBER PART NAME F3AZ-19515-SA Super Seal Anti-Corrosion compound 8A-19522-A Custom Bright Metal cleaner OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 980113A Apply Sealer - Front 0.8 Hr. Bumper - 1997-98 Expedition/F-150-250 LD 4X4 Under 8500 Lbs GVW 980113B Apply Sealer - Front 0.5 Hr. Bumper - 1997-98 F-150-250 LD 4X2 Under 8500 Lbs GVW 980113C Apply Sealer - Rear 0.4 Hr. Bumper - 1997-98 F-150-250 LD 4X2/4X4 Under 8500 Lbs GVW 980113D Apply Sealer - Front 0.5 Hr. Bumper - 1990-97 F-250 HD/F-350/Bronco 980113E Apply Sealer - Rear 0.4 Hr. Bumper - 1990-97 F-250 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Bumper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Bumper: > 01-16-6 > Aug > 01 > Customer Interest for Bumper: > 98-1-13 > Jan > 98 > Bumper - Rust Staining > Page 11052 HD/F-350/Bronco 980113F Apply Sealer - Rear 0.6 Hr. Bumper - 1997-98 Expedition 980113G Apply Sealer - Front 0.5 Hr. Bumper - 1997 Explorer XLT/Eddie Bauer 980113H Apply Sealer - Rear 0.5 Hr. Bumper - 1997 Explorer 9801131 Apply Sealer - Front 0.5 Hr. Bumper - 1997 Econoline DEALER CODING CONDITION BASIC PART NO. CODE 17757 68 OASIS CODES: 106000 1997-98 Expedition/F-150/250 LD 4X4 Frnt. Bumper 1997-98 EXPEDITION AND F-150/250 LD 4X4 FRONT BUMPER 1. Turn off air suspension if applicable. 2. Hoist vehicle until bumper is at working level. 3. Remove the fog lamps or fog lamp blanks. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Bumper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Bumper: > 01-16-6 > Aug > 01 > Customer Interest for Bumper: > 98-1-13 > Jan > 98 > Bumper - Rust Staining > Page 11053 4. Mask the front face of the center at air opening and both fog lamp openings (Figure 1). 5. Disconnect fog lamp wiring and block heater wires from the bumper. 6. Disconnect the three (3) push pins for the splash guard. 7. Clean excessive dirt from inside and outside the bumper. 8. Spray the edges of the three (3) openings with Super Seal Anti-Corrosion Compound. 9. Remove the tape from the fog lamp openings so as not to get the Super Seal Anti-Corrosion Compound on the fog lamps during reinstallation. 10. Reinstall the fog lamps/fog lamp blanks. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Bumper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Bumper: > 01-16-6 > Aug > 01 > Customer Interest for Bumper: > 98-1-13 > Jan > 98 > Bumper - Rust Staining > Page 11054 11. Plug in fog lamp wiring and push pins for the block heater connector and lower valance push pins. 12. Lower vehicle and turn on air suspension if so equipped. 13. Clean vent and fog lamp openings as needed. 1997-98 F-150/250 LD 4X2 Front Bumper 1997-98 F-150/250 LD 4X2 FRONT BUMPER 1. Turn off air suspension it applicable. 2. Hoist vehicle until bumper is at working level. 3. Clean excessive dirt from inside and outside the bumper. 4. Remove the five (5) push pins to the radiator support. 5. Spray the edges of the air intake opening and the bumper cover retainer openings and drain holes with Super Seal Anti-Corrosion Compound. 6. Reinstall the push pins and remove the tape. 7. Lower vehicle and turn on air suspension if so equipped. 8. Clean off overspray as needed. 1997-98 F-150/250 LD Rear Bumper (4X2/4X4) 1997-98 F-150/250 LD REAR BUMPER (4X2 AND 4X4) 1. Turn off air suspension if applicable. 2. Hoist vehicle until bumper is at working level. 3. Clean excessive dirt from inside and outside the bumper. 4. Spray the back of the bumper from underneath the vehicle. Make sure to spray the license plate lights, openings, and the bumper pad retaining holes with Super Seal Anti-Corrosion Compound. 5. Lower vehicle and turn on air suspension if so equipped. 6. Clean off overspray as needed. 1990-97 F-250 HD/F-350/Bronco Frnt./Rear Bumper 1990-97 F-250 HD/F-350/BRONCO - FRONT BUMPER 1. Hoist vehicle until bumper is at working level. 2. Remove the lower valance out of the way to allow access to inside of front bumper. 3. Clean excessive dirt from inside and outside the bumper. 4. Tape license plate bolt holes. 5. Spray the edge of the opening and the bolt opening area including the license plate lights bracket holes with Super Seal Anti-Corrosion Compound. 6. Reinstall lower valance. 7. Remove protective tape. 8. Lower vehicle. 9. Clean off overspray as needed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Bumper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Bumper: > 01-16-6 > Aug > 01 > Customer Interest for Bumper: > 98-1-13 > Jan > 98 > Bumper - Rust Staining > Page 11055 1990-97 F-250 HD/F-350/BRONCO - REAR BUMPER 1. Install newspaper between the tailgate and the bumper top cover to prevent spray on the tailgate. 2. Hoist vehicle until bumper is at working level. 3. Clean excessive dirt from inside and outside the bumper. 4. Spray the back side of the bumper from underneath the vehicle. Make sure to spray the license plate light opening, and the bolt mounting areas above the bumper mounting bracket to prevent water from leaking to the front from the back side. Also spray the bumper pad retaining holes. 5. Lower vehicle. 6. Remove paper and clean off overspray as needed. 1997-98 Expedition - Rear Bumper 1997-98 EXPEDITION - REAR BUMPER 1. Turn off air suspension, if equipped. 2. Remove spare tire. 3. Hoist vehicle until bumper is at working level. 4. Clean excessive dirt from inside and outside the bumper. 5. Spray the back of the bumper from underneath the vehicle with Super Seal Anti-Corrosion Compound. 6. Lower vehicle and turn on air suspension if so equipped. 7. Reinstall spare tire. 8. Clean off overspray as needed. 1997 Explorer XLT/Eddie Bauer - Frnt. Bumper 1997 EXPLORER XLT/EDDIE BAUER - FRONT BUMPER 1. Hoist vehicle until bumper is at working level. 2. Remove the four (4) screws and two (2) push pins from the lower valance of the radiator and remove valance. 3. Tape the air intake openings in the bumper (Figure 1). Removal of the license plate bracket is not required. 4. Clean excessive dirt from inside and outside the bumper. 5. Spray the edge of the air intake opening and the bumper cover retainer openings with Super Seal Anti-Corrosion Compound. 6. Remove tape and reinstall the radiator lower valance. 7. Lower vehicle. 8. Clean off overspray as needed. 1997 Explorer - Rear Bumper 1997 EXPLORER - REAR BUMPER 1. Remove spare tire. 2. Hoist vehicle until bumper is at working level. 3. Clean excessive dirt from inside and outside the bumper. A light amount will not affect the effectiveness of the Super Seal Anti-Corrosion Compound. 4. Spray the back of the bumper with Super Seal Anti-Corrosion Compound paying close attention to the areas around the license plate lights and the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Bumper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Bumper: > 01-16-6 > Aug > 01 > Customer Interest for Bumper: > 98-1-13 > Jan > 98 > Bumper - Rust Staining > Page 11056 top cover retaining tab openings in the bumper. These are the areas that let the back side rust bleed to the front of the bumper and cause stain. 5. Lower vehicle. 6. Reinstall spare tire. 7. Clean off overspray as needed. 1997 Econoline - Front Bumper 1997 ECONOLINE - FRONT BUMPER 1. Hoist vehicle until bumper is at working level. 2. Remove the two (2) lower valance push pins and remove valance. 3. Tape the air intake opening. 4. Clean excessive dirt from inside and outside the bumper. 5. Spray the edge of the air intake opening and the bumper cover retainer openings with Super Seal Anti-Corrosion Compound. 6. Remove tape and reinstall the lower valance push pins. 7. Lower vehicle. 8. Clean off overspray as needed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Bumper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Stabilizer Bushing: > 98-1-13 > Jan > 98 > Bumper - Rust Staining Technical Service Bulletin # 98-1-13 Date: 980119 Bumper - Rust Staining Article No. 98-1-13 01/19/98 BUMPER - RUST STAIN - EDGES OF CENTER VENT AND FOG LAMP OPENINGS LIGHT TRUCK: 1990-96 BRONCO 1990-97 F-250 HD, F-350 1997 ECONOLINE, EXPLORER 1997-98 EXPEDITION, F-150, F-250 LD ISSUE: Red rust stains on the edges of the bumper center vent and fog lamp openings may appear on some vehicles. ACTION: Apply Super Seal Anti-Corrosion Compound to the affected areas of the bumper. Refer to the following Service Procedures for details. NOTE: USE A PROTECTIVE GLOVE FOR APPLYING BOTH THE CUSTOM BRIGHT METAL CLEANER (8A-19522-A) AND THE SUPER SEAL ANTI-CORROSION COMPOUND (F3AZ-19515-SA). For each of the specific vehicle procedures found in this TSB article, be sure the following 3 steps are done: 1. Clean the red rust stain from the inside and chrome surface of the bumper. 2. Paint the edge of openings and at least 25 mm (1") area around the inside of the bumper vent and fog lamp openings. 3. Spray around the top cover attachment holes/slots. PART NUMBER PART NAME F3AZ-19515-SA Super Seal Anti-Corrosion compound 8A-19522-A Custom Bright Metal cleaner OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 980113A Apply Sealer - Front 0.8 Hr. Bumper - 1997-98 Expedition/F-150-250 LD 4X4 Under 8500 Lbs GVW 980113B Apply Sealer - Front 0.5 Hr. Bumper - 1997-98 F-150-250 LD 4X2 Under 8500 Lbs GVW 980113C Apply Sealer - Rear 0.4 Hr. Bumper - 1997-98 F-150-250 LD 4X2/4X4 Under 8500 Lbs GVW 980113D Apply Sealer - Front 0.5 Hr. Bumper - 1990-97 F-250 HD/F-350/Bronco 980113E Apply Sealer - Rear 0.4 Hr. Bumper - 1990-97 F-250 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Bumper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Stabilizer Bushing: > 98-1-13 > Jan > 98 > Bumper - Rust Staining > Page 11062 HD/F-350/Bronco 980113F Apply Sealer - Rear 0.6 Hr. Bumper - 1997-98 Expedition 980113G Apply Sealer - Front 0.5 Hr. Bumper - 1997 Explorer XLT/Eddie Bauer 980113H Apply Sealer - Rear 0.5 Hr. Bumper - 1997 Explorer 9801131 Apply Sealer - Front 0.5 Hr. Bumper - 1997 Econoline DEALER CODING CONDITION BASIC PART NO. CODE 17757 68 OASIS CODES: 106000 1997-98 Expedition/F-150/250 LD 4X4 Frnt. Bumper 1997-98 EXPEDITION AND F-150/250 LD 4X4 FRONT BUMPER 1. Turn off air suspension if applicable. 2. Hoist vehicle until bumper is at working level. 3. Remove the fog lamps or fog lamp blanks. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Bumper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Stabilizer Bushing: > 98-1-13 > Jan > 98 > Bumper - Rust Staining > Page 11063 4. Mask the front face of the center at air opening and both fog lamp openings (Figure 1). 5. Disconnect fog lamp wiring and block heater wires from the bumper. 6. Disconnect the three (3) push pins for the splash guard. 7. Clean excessive dirt from inside and outside the bumper. 8. Spray the edges of the three (3) openings with Super Seal Anti-Corrosion Compound. 9. Remove the tape from the fog lamp openings so as not to get the Super Seal Anti-Corrosion Compound on the fog lamps during reinstallation. 10. Reinstall the fog lamps/fog lamp blanks. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Bumper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Stabilizer Bushing: > 98-1-13 > Jan > 98 > Bumper - Rust Staining > Page 11064 11. Plug in fog lamp wiring and push pins for the block heater connector and lower valance push pins. 12. Lower vehicle and turn on air suspension if so equipped. 13. Clean vent and fog lamp openings as needed. 1997-98 F-150/250 LD 4X2 Front Bumper 1997-98 F-150/250 LD 4X2 FRONT BUMPER 1. Turn off air suspension it applicable. 2. Hoist vehicle until bumper is at working level. 3. Clean excessive dirt from inside and outside the bumper. 4. Remove the five (5) push pins to the radiator support. 5. Spray the edges of the air intake opening and the bumper cover retainer openings and drain holes with Super Seal Anti-Corrosion Compound. 6. Reinstall the push pins and remove the tape. 7. Lower vehicle and turn on air suspension if so equipped. 8. Clean off overspray as needed. 1997-98 F-150/250 LD Rear Bumper (4X2/4X4) 1997-98 F-150/250 LD REAR BUMPER (4X2 AND 4X4) 1. Turn off air suspension if applicable. 2. Hoist vehicle until bumper is at working level. 3. Clean excessive dirt from inside and outside the bumper. 4. Spray the back of the bumper from underneath the vehicle. Make sure to spray the license plate lights, openings, and the bumper pad retaining holes with Super Seal Anti-Corrosion Compound. 5. Lower vehicle and turn on air suspension if so equipped. 6. Clean off overspray as needed. 1990-97 F-250 HD/F-350/Bronco Frnt./Rear Bumper 1990-97 F-250 HD/F-350/BRONCO - FRONT BUMPER 1. Hoist vehicle until bumper is at working level. 2. Remove the lower valance out of the way to allow access to inside of front bumper. 3. Clean excessive dirt from inside and outside the bumper. 4. Tape license plate bolt holes. 5. Spray the edge of the opening and the bolt opening area including the license plate lights bracket holes with Super Seal Anti-Corrosion Compound. 6. Reinstall lower valance. 7. Remove protective tape. 8. Lower vehicle. 9. Clean off overspray as needed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Bumper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Stabilizer Bushing: > 98-1-13 > Jan > 98 > Bumper - Rust Staining > Page 11065 1990-97 F-250 HD/F-350/BRONCO - REAR BUMPER 1. Install newspaper between the tailgate and the bumper top cover to prevent spray on the tailgate. 2. Hoist vehicle until bumper is at working level. 3. Clean excessive dirt from inside and outside the bumper. 4. Spray the back side of the bumper from underneath the vehicle. Make sure to spray the license plate light opening, and the bolt mounting areas above the bumper mounting bracket to prevent water from leaking to the front from the back side. Also spray the bumper pad retaining holes. 5. Lower vehicle. 6. Remove paper and clean off overspray as needed. 1997-98 Expedition - Rear Bumper 1997-98 EXPEDITION - REAR BUMPER 1. Turn off air suspension, if equipped. 2. Remove spare tire. 3. Hoist vehicle until bumper is at working level. 4. Clean excessive dirt from inside and outside the bumper. 5. Spray the back of the bumper from underneath the vehicle with Super Seal Anti-Corrosion Compound. 6. Lower vehicle and turn on air suspension if so equipped. 7. Reinstall spare tire. 8. Clean off overspray as needed. 1997 Explorer XLT/Eddie Bauer - Frnt. Bumper 1997 EXPLORER XLT/EDDIE BAUER - FRONT BUMPER 1. Hoist vehicle until bumper is at working level. 2. Remove the four (4) screws and two (2) push pins from the lower valance of the radiator and remove valance. 3. Tape the air intake openings in the bumper (Figure 1). Removal of the license plate bracket is not required. 4. Clean excessive dirt from inside and outside the bumper. 5. Spray the edge of the air intake opening and the bumper cover retainer openings with Super Seal Anti-Corrosion Compound. 6. Remove tape and reinstall the radiator lower valance. 7. Lower vehicle. 8. Clean off overspray as needed. 1997 Explorer - Rear Bumper 1997 EXPLORER - REAR BUMPER 1. Remove spare tire. 2. Hoist vehicle until bumper is at working level. 3. Clean excessive dirt from inside and outside the bumper. A light amount will not affect the effectiveness of the Super Seal Anti-Corrosion Compound. 4. Spray the back of the bumper with Super Seal Anti-Corrosion Compound paying close attention to the areas around the license plate lights and the Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Bumper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Stabilizer Bushing: > 98-1-13 > Jan > 98 > Bumper - Rust Staining > Page 11066 top cover retaining tab openings in the bumper. These are the areas that let the back side rust bleed to the front of the bumper and cause stain. 5. Lower vehicle. 6. Reinstall spare tire. 7. Clean off overspray as needed. 1997 Econoline - Front Bumper 1997 ECONOLINE - FRONT BUMPER 1. Hoist vehicle until bumper is at working level. 2. Remove the two (2) lower valance push pins and remove valance. 3. Tape the air intake opening. 4. Clean excessive dirt from inside and outside the bumper. 5. Spray the edge of the air intake opening and the bumper cover retainer openings with Super Seal Anti-Corrosion Compound. 6. Remove tape and reinstall the lower valance push pins. 7. Lower vehicle. 8. Clean off overspray as needed. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems Technical Service Bulletin # 98-9-13 Date: 980511 Body/Frame - Water Leaks Causing Electrical Problems Article No. 98-9-13 05/11/98 ^ WATER LEAKS - VARIOUS AREAS OF VEHICLE ^ ELECTRICAL - ACCESSORIES FUNCTIONING IMPROPERLY DUE TO WATER LEAKS ^ LAMPS - WARNING LAMPS ILLUMINATED DUE TO WATER LEAKS LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR This TSB article is being republished in its entirety to add F-150, F-250 LD, and Navigator vehicles, and to revise the text and art accordingly. ISSUE Water leaks in various areas of the vehicle as identified below may be causing electrical concerns such as: ^ Warning lamps illuminating, and/or ^ Improper wiper operation, and/or ^ Improper function of electrical accessories The water leaks may be caused by sealer skips, unseated grommets, and/or clogged drain tubes. ACTION Repair the water leaks. Refer to the following Service Procedures for details on: ^ Windshield Leaks ^ Cowl Top Leaks ^ Cowl Side-to-Door Opening Panel Leaks ^ Cowl Side-to-Dash Panel Leaks ^ Moon roof Leaks ^ Grommets The following procedures may include using a seam sealer for repairs. Recommended seam sealers are: Company Part Name Phone Number 3M Ultrapro Seam Sealer (612) 733-5547 - US Kent Uniweld Seam Sealer (800) 654-6333 - US (800) 663-2800 - Canada OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-19-15 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11075 980913A Windshield Leaks Service 0.5 Hr. Procedure 980913B Additional Time If Leaf 0.4 Hr. Screen Must Be Removed (Used With Operation A) 980913C Cowl Top Leaks Service 1.3 Hrs. Procedure 980913D Cowl Side-To-Door 1.9 Hrs. Opening Panel Leaks Service Procedure 980913E Cowl Side-To-Dash Panel 0.4 Hr. Leaks Service Procedure 980913F Moonroof Leaks Service 0.4 Hr. Procedure 980913G Grommets Service 0.4 Hr. Procedure DEALER CODING CONDITION BASIC PART NO. CODE 18812 GROMMET(S) LEAKS 68 7801610 COWL TOP LEAKS (DASH PANEL) 68 7802012 COWL TOP LEAKS (OUTER) 68 7802018 COWL SIDE TO-DASH PANEL LEAKS 68 7802039 COWL SIDE-TO-DOOR OPENING PANEL LEAKS 68 7803100 WINDSHIELD LEAKS 68 78502C53 MOON ROOF LEAKS 68 OASIS CODES: 110000,190000, 202000, 203000, 205000, 206000 Windshield Leaks Service Procedure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11076 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11077 Refer To Figures 1, 2, and 3 1. Remove A-pillar mouldings, rocker panel scuff plates, and cowl lower scuff plates. Refer to the appropriate Workshop Manual, Section 501-05. 2. Apply a water hose at the bottom center of the windshield and slowly move outboard at a rate of 305 mm (1 foot) per 15-20 seconds. Then move up one side, inboard along top of header to the center. Lift the moulding at top of windshield to allow water to pass through windshield moulding. NOTE A NARROW NYLON TIP ON THE END OF THE HOSE WILL ALLOW THE OPERATOR TO EASILY SLIDE THE TIP UNDER THE MOULDING AND SLOWLY MOVE IT ALONG THE INSIDE SURFACE. 3. To determine if water is entering, have an observer use a flashlight to watch for water as the hose is being moved. The observer should start looking at the dash back panel by pulling back the dash insulator pad above the water location. 4. If a leak is detected, document the location and path for future reference. 5. Fill any voids with pumpable Butyl Sealer. NOTE TO REPAIR WATER LEAKS FOUND AT THE BASE OF THE WINDSHIELD, THE LEAF SCREEN MUST FIRST BE REMOVED. Cowl Top Leaks Service Procedure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11078 Refer To Figure 4 1. Remove the leaf screen by referring to the appropriate Workshop Manual, Section 501-02. 2. Spray water into cowl top-to-dash panel seam. Spray for up to 20 minutes. 3. Inspect the inner dash panel for water intrusion, starting at the bottom of the cowl area. 4. With the trim rocker cover and kick plate removed, pull back carpet and inspect for water. 5. If no water is found, look in the area of the cross car beam and/or lower windshield "VIN tag" area. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11079 6. Seal inner cowl with seam sealer. Cowl Side-to-Door Opening Panel Leaks Service Procedure Refer To Figure 5 1. Remove the left front tire. 2. Remove the inner fender splash shield from the left front fender. Refer to the appropriate Workshop Manual, Section 501-02, for details. 3. Remove the grille by referring to the Workshop Manual, Section 501-08. 4. Remove the left front fender by referring to the Workshop Manual, Section 501-02. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11080 5. Test with water. 6. Apply seam sealer along the interface between the cowl and the dash panel. This area can be reached through the access hole located near the top hinge for the front door. 7. Reassemble in reverse order. 8. Apply paint protection to fender bolts. Cowl Side-to-Dash Panel Leaks Service Procedure Refer To Figure 6 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11081 1. Remove rocker cover and lower scuff panel by referring to the appropriate Workshop Manual, Section 501-05. 2. Inspect dash panel-to-cowl side inner sealer for skips and/or missing sealer. 3. Test with water at the top of the cowl/leaf screen area and inspect the vehicle for water entry. 4. Apply seam sealer along the interface between the cowl, dash, and floor panel. Moonroof Leaks Service Procedure Refer To Figure 7 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11082 1. Before beginning any diagnosis, contact the Webasto Tech Hotline at (800) 995-5911 Monday-Friday, 9AM-6PM EST. 2. Cycle moonroof to open position. 3. Check for proper drain tube action by pouring approximately 1.8L (6 oz) of water into trough at each side. 4. If tubes appear to be draining properly, remove the interior A-pillar trim and sun visors. Refer to the appropriate Workshop Manual, Section 501-05. 5. Pull down the headliner slightly and inspect moonroof drain tubes for kinks and/or twists. The drain tubes must be free from any bends or obstruction of water flow. 6. Straighten or cut drain tubes to proper length to allow for free draining. Grommets Service Procedure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11083 Refer To Figure 8 1. Check for missing or improperly seated grommets in the following areas: ^ Antenna grommet on passenger side cowl ^ Park brake cable grommet on driver side cowl ^ Overall instrument panel grommets 2. Reseat any loose grommets or replace any missing grommets. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems Technical Service Bulletin # 98-9-13 Date: 980511 Body/Frame - Water Leaks Causing Electrical Problems Article No. 98-9-13 05/11/98 ^ WATER LEAKS - VARIOUS AREAS OF VEHICLE ^ ELECTRICAL - ACCESSORIES FUNCTIONING IMPROPERLY DUE TO WATER LEAKS ^ LAMPS - WARNING LAMPS ILLUMINATED DUE TO WATER LEAKS LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR This TSB article is being republished in its entirety to add F-150, F-250 LD, and Navigator vehicles, and to revise the text and art accordingly. ISSUE Water leaks in various areas of the vehicle as identified below may be causing electrical concerns such as: ^ Warning lamps illuminating, and/or ^ Improper wiper operation, and/or ^ Improper function of electrical accessories The water leaks may be caused by sealer skips, unseated grommets, and/or clogged drain tubes. ACTION Repair the water leaks. Refer to the following Service Procedures for details on: ^ Windshield Leaks ^ Cowl Top Leaks ^ Cowl Side-to-Door Opening Panel Leaks ^ Cowl Side-to-Dash Panel Leaks ^ Moon roof Leaks ^ Grommets The following procedures may include using a seam sealer for repairs. Recommended seam sealers are: Company Part Name Phone Number 3M Ultrapro Seam Sealer (612) 733-5547 - US Kent Uniweld Seam Sealer (800) 654-6333 - US (800) 663-2800 - Canada OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-19-15 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11089 980913A Windshield Leaks Service 0.5 Hr. Procedure 980913B Additional Time If Leaf 0.4 Hr. Screen Must Be Removed (Used With Operation A) 980913C Cowl Top Leaks Service 1.3 Hrs. Procedure 980913D Cowl Side-To-Door 1.9 Hrs. Opening Panel Leaks Service Procedure 980913E Cowl Side-To-Dash Panel 0.4 Hr. Leaks Service Procedure 980913F Moonroof Leaks Service 0.4 Hr. Procedure 980913G Grommets Service 0.4 Hr. Procedure DEALER CODING CONDITION BASIC PART NO. CODE 18812 GROMMET(S) LEAKS 68 7801610 COWL TOP LEAKS (DASH PANEL) 68 7802012 COWL TOP LEAKS (OUTER) 68 7802018 COWL SIDE TO-DASH PANEL LEAKS 68 7802039 COWL SIDE-TO-DOOR OPENING PANEL LEAKS 68 7803100 WINDSHIELD LEAKS 68 78502C53 MOON ROOF LEAKS 68 OASIS CODES: 110000,190000, 202000, 203000, 205000, 206000 Windshield Leaks Service Procedure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11090 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11091 Refer To Figures 1, 2, and 3 1. Remove A-pillar mouldings, rocker panel scuff plates, and cowl lower scuff plates. Refer to the appropriate Workshop Manual, Section 501-05. 2. Apply a water hose at the bottom center of the windshield and slowly move outboard at a rate of 305 mm (1 foot) per 15-20 seconds. Then move up one side, inboard along top of header to the center. Lift the moulding at top of windshield to allow water to pass through windshield moulding. NOTE A NARROW NYLON TIP ON THE END OF THE HOSE WILL ALLOW THE OPERATOR TO EASILY SLIDE THE TIP UNDER THE MOULDING AND SLOWLY MOVE IT ALONG THE INSIDE SURFACE. 3. To determine if water is entering, have an observer use a flashlight to watch for water as the hose is being moved. The observer should start looking at the dash back panel by pulling back the dash insulator pad above the water location. 4. If a leak is detected, document the location and path for future reference. 5. Fill any voids with pumpable Butyl Sealer. NOTE TO REPAIR WATER LEAKS FOUND AT THE BASE OF THE WINDSHIELD, THE LEAF SCREEN MUST FIRST BE REMOVED. Cowl Top Leaks Service Procedure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11092 Refer To Figure 4 1. Remove the leaf screen by referring to the appropriate Workshop Manual, Section 501-02. 2. Spray water into cowl top-to-dash panel seam. Spray for up to 20 minutes. 3. Inspect the inner dash panel for water intrusion, starting at the bottom of the cowl area. 4. With the trim rocker cover and kick plate removed, pull back carpet and inspect for water. 5. If no water is found, look in the area of the cross car beam and/or lower windshield "VIN tag" area. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11093 6. Seal inner cowl with seam sealer. Cowl Side-to-Door Opening Panel Leaks Service Procedure Refer To Figure 5 1. Remove the left front tire. 2. Remove the inner fender splash shield from the left front fender. Refer to the appropriate Workshop Manual, Section 501-02, for details. 3. Remove the grille by referring to the Workshop Manual, Section 501-08. 4. Remove the left front fender by referring to the Workshop Manual, Section 501-02. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11094 5. Test with water. 6. Apply seam sealer along the interface between the cowl and the dash panel. This area can be reached through the access hole located near the top hinge for the front door. 7. Reassemble in reverse order. 8. Apply paint protection to fender bolts. Cowl Side-to-Dash Panel Leaks Service Procedure Refer To Figure 6 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11095 1. Remove rocker cover and lower scuff panel by referring to the appropriate Workshop Manual, Section 501-05. 2. Inspect dash panel-to-cowl side inner sealer for skips and/or missing sealer. 3. Test with water at the top of the cowl/leaf screen area and inspect the vehicle for water entry. 4. Apply seam sealer along the interface between the cowl, dash, and floor panel. Moonroof Leaks Service Procedure Refer To Figure 7 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11096 1. Before beginning any diagnosis, contact the Webasto Tech Hotline at (800) 995-5911 Monday-Friday, 9AM-6PM EST. 2. Cycle moonroof to open position. 3. Check for proper drain tube action by pouring approximately 1.8L (6 oz) of water into trough at each side. 4. If tubes appear to be draining properly, remove the interior A-pillar trim and sun visors. Refer to the appropriate Workshop Manual, Section 501-05. 5. Pull down the headliner slightly and inspect moonroof drain tubes for kinks and/or twists. The drain tubes must be free from any bends or obstruction of water flow. 6. Straighten or cut drain tubes to proper length to allow for free draining. Grommets Service Procedure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11097 Refer To Figure 8 1. Check for missing or improperly seated grommets in the following areas: ^ Antenna grommet on passenger side cowl ^ Park brake cable grommet on driver side cowl ^ Overall instrument panel grommets 2. Reseat any loose grommets or replace any missing grommets. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair Front Door Exterior Handle: Service and Repair Outside Handle and Lock Cylinder, Front Door Removal 1. NOTE: Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. Remove the front door trim panel. 2. NOTE: The front door window glass must be completely up. Remove the outside front door handle. 1. Disconnect the front door latch to lock cylinder rod. 2. Disconnect the front door latch to outside front door handle rod at the handle and at the latch. 3. Remove the two outside front door handle nuts. 4. Remove the outside front door handle by pushing it out from the bottom surface of the handle. 3. Remove the front door look cylinder. 1. Remove the retainer. 2. Remove the front door lock cylinder. Installation 1. NOTE: Make sure the door handle and rods are in a relaxed position and that the rod is all the way up before closing the clips. To install reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip Front Door Panel: Technical Service Bulletins Interior Door Trim Panel - Replacement Tip Article No. 99-8-15 05/03/99 INTERIOR TRIM - DOOR TRIM PANEL REPLACEMENT - SERVICE TIP FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, MUSTANG 1996-1999 ESCORT, TAURUS 1998-1999 ESCORT ZX2 LINCOLN-MERCURY: 1993-1998 MARK VIII 1995-1997 COUGAR 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, TOWN CAR 1996-1999 SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1993-1996 BRONCO 1993-1997 F SUPER DUTY, F-250 HD, F-350 1993-1999 F-150, F-250 LD 1995-1997 AEROSTAR 1995-1999 ECONOLINE, EXPLORER, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE There has been an increase in the number of door trim panel replacements due to damage. This may be caused by a misconception of the type of fastener used to secure the door trim panel. ACTION Review the appropriate model/year Service/Workshop Manual, Section 01-05/501-05 prior to removing the door trim panel. Use the Quick Reference Guide at the end of this article to determine the type of fastener used for the vehicle being worked on. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip > Page 11109 For a door trim panel with "molded hook" design, Figure 1 displays the correct direction of force applied during the door trim panel removal procedure. Refer to the Door Trim Panel Attachment Scheme Chart to identify vehicles with molded hook designs. WARNING REMOVE ALL THE SCREWS AND TWO-STAGE PINS BEFORE ATTEMPTING TO REMOVE TRIM PANEL. Detailed instructions and illustration can be found in the appropriate model/year Service/Workshop Manual, Section 01-05/501-05. OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip > Page 11110 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 107000,112000,190000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Page 11111 Front Door Panel: Service and Repair Removal 1. NOTE: Release the top portion first. Remove the sail panel. 2. Remove the window regulator switch plate. 3. Disconnect the electrical connectors. 4. Remove the upper door trim panel screw. 5. Remove the door trim panel screw at the window regulator switch plate opening. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Page 11112 6. Remove the door trim panel screw in the courtesy lamp housing. 1. Remove the courtesy lamp lens. 2. Remove the screw. 7. Remove the inside door handle trim cover. 8. Remove the inside door handle. - Remove the bolt. 9. CAUTION: To avoid damage to the front door trim panel, do not pull directly outward. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Page 11113 Lift upward and then outward to remove the front door trim panel. 10. Remove the courtesy lamp and socket. 11. Disconnect the power mirror electrical connector. Installation 1. Connect the power mirror electrical connector. 2. Install the courtesy lamp and socket. 3. Install the front door trim panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Page 11114 4. Install the inside door handle. - Install the bolt. 5. Install the inside door handle trim cover. 6. Install the door trim panel screw in the courtesy lamp housing. 1. Install the screw. 2. Install the courtesy lamp lens. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Page 11115 7. Install the door trim panel screw at the window regulator switch plate opening. 8. Install the upper door trim panel screw. 9. Connect the electrical connectors. 10. NOTE: If a new trim panel is required: Some new trim panels have a cut out opening for the window switchplate that is larger than that on the original trim panel. When installing a new trim panel, install the window switchplate in the following sequence to make sure that the switchplate is secured fully into the door trim panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Page 11116 Install the window regulator switchplate. - Insert the rear switchplate clip into the trim panel opening. - Install the forward and side clips into the trim panel opening. 11. NOTE: Install the lower portion first. Install the sail panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Service and Repair Front Door Window Glass: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Remove the front door watershield. 3. Lower the window glass to access the two window glass to regulator nuts. 4. Remove the inside glass weatherstrip. 5. Remove the rear glass channel bolt and lift the channel. 6. Remove the two window glass to regulator nuts. 7. Remove the front door window glass. NOTE: Slide the glass through the outboard side of the door. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Service and Repair > Page 11120 INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair Front Door Window Regulator: Service and Repair Heavy Duty Riverter Special Tool(s) REMOVAL 1. Remove the front door trim panel. 2. Raise and support the front door window glass to the full up position. 3. Disconnect the power window motor electrical connector. 4. Remove the nuts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Page 11124 5. Remove the motor and window regulator assembly. 1. Drill out the rivets. 2. Remove the motor and window regulator. 6. Remove the power window motor. 1. Remove the bolts. 2. Remove the power window motor. NOTE: Prior to motor removal, ensure the regulator arms are in a fixed position to prevent counterbalance spring unwind. INSTALLATION 1. To install, reverse the removal procedure. - Use Heavy Duty Riveter to install the new rivets. - Cycle the door glass to ensure gear engagement. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair Rear Door Exterior Handle: Service and Repair Outside Door Handle, Rear Door Removal 1. Remove the rear door trim panel. 2. Remove the outside rear door handle. 1. Remove the nuts. 2. Disconnect the rear door latch to outside rear door handle rod. 3. Remove the outside rear door handle by pushing it out from the bottom surface of the handle. Installation 1. NOTE: Make sure the door handle and rods are in a relaxed position and that the rod is all the way up before closing the clips. To match reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip Rear Door Panel: Technical Service Bulletins Interior Door Trim Panel - Replacement Tip Article No. 99-8-15 05/03/99 INTERIOR TRIM - DOOR TRIM PANEL REPLACEMENT - SERVICE TIP FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, MUSTANG 1996-1999 ESCORT, TAURUS 1998-1999 ESCORT ZX2 LINCOLN-MERCURY: 1993-1998 MARK VIII 1995-1997 COUGAR 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, TOWN CAR 1996-1999 SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1993-1996 BRONCO 1993-1997 F SUPER DUTY, F-250 HD, F-350 1993-1999 F-150, F-250 LD 1995-1997 AEROSTAR 1995-1999 ECONOLINE, EXPLORER, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE There has been an increase in the number of door trim panel replacements due to damage. This may be caused by a misconception of the type of fastener used to secure the door trim panel. ACTION Review the appropriate model/year Service/Workshop Manual, Section 01-05/501-05 prior to removing the door trim panel. Use the Quick Reference Guide at the end of this article to determine the type of fastener used for the vehicle being worked on. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip > Page 11134 For a door trim panel with "molded hook" design, Figure 1 displays the correct direction of force applied during the door trim panel removal procedure. Refer to the Door Trim Panel Attachment Scheme Chart to identify vehicles with molded hook designs. WARNING REMOVE ALL THE SCREWS AND TWO-STAGE PINS BEFORE ATTEMPTING TO REMOVE TRIM PANEL. Detailed instructions and illustration can be found in the appropriate model/year Service/Workshop Manual, Section 01-05/501-05. OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip > Page 11135 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 107000,112000,190000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Page 11136 Rear Door Panel: Service and Repair Removal 1. Remove the window regulator switchplate. 2. Disconnect the electrical connector. 3. Remove the rear door handle trim cover. 4. Remove the rear inside door handle. - Remove the door handle bolt. 5. Remove the rear door trim panel screws. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Page 11137 6. CAUTION: To avoid damage to the rear door trim panel, do not pull directly outward. Lift upward and then outward to remove the rear door trim panel. Installation 1. Install the rear door trim panel. 2. Install the rear door trim panel screws. 3. Install the rear inside door handle. - Install the door handle bolt. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Page 11138 4. Install the rear door handle trim cover. 5. Connect the electrical connector. 6. NOTE: If a new trim panel is required: Some new trim panels have a cut out opening for the window switchplate that is larger than that on the original trim panel. When installing a new trim panel, install the window switchplate in the following sequence to make sure that the switchplate is secured fully into the door trim panel. 7. Install the window regulator switchplate. - Insert the rear switchplate clip into the trim panel opening. - Install the forward and side clips into the trim panel opening. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair Rear Door Window Glass: Service and Repair REMOVAL 1 Remove the rear door trim panel. 2. Remove the rear door watershield. 3. Remove the inside glass weatherstrip. 4. Remove the door glass channel bolt. 5. Remove the rear door fixed vent screw. 6. Lift the rear door rear glass and channel away from the door glass. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair > Page 11142 7. Remove the two window glass to regulator nuts. 8. Remove the rear door glass. NOTE: Slide the glass through the outboard side of the door. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Specifications Rear Door Window Regulator: Specifications Window Regulator Nuts ....................................................................................................................... ............................................ 10-14 Nm (7.4-10 ft lb) Window Glass to Regulator Nuts ..................................................................................................................................................... 10-14 Nm (7.4-10 ft lb) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Specifications > Page 11146 Rear Door Window Regulator: Service and Repair Heavy Duty Riverter Special Tool(s) REMOVAL 1. Remove the rear door trim panel. 2. Raise and support the rear door window glass to the full up position. 3. Disconnect the power window motor electrical connector. 4. Remove the nuts. 5. Remove the motor and window regulator assembly. 1. Drill out the rivets. 2. Remove the motor and window regulator. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Specifications > Page 11147 6. Remove the power window motor. 1. Remove the bolts. 2. Remove the power window motor. NOTE: Prior to motor removal, ensure the regulator arms are in a fixed position to prevent counterbalance spring unwind. INSTALLATION 1. To install, reverse the removal procedure. - Use Heavy Duty Riveter to install the new rivets. - Cycle the door glass to ensure gear engagement. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair Liftgate Window Glass: Service and Repair REMOVAL 1. Remove the heated backlite connectors. 1. Unclip the connector shell. 2. Remove the wires from the terminals. 2. Remove the liftgate window glass. 1. Remove the E-clip. 2. Remove the pin. 3. Remove the strut. NOTE: Have an assistant hold the liftgate window glass. 3. Remove the liftgate window glass. 1. Remove the four screws (two each side). 2. Remove the liftgate window glass. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair > Page 11152 INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Trunk / Liftgate Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 11157 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 11158 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 11159 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 11160 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 11161 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Specifications Cross-Member: Specifications Torsion Bar Crossmember Support Bolts .................................................................................................................................. 40-54 Nm (29-39 ft. lbs.) Torsion Bar Crossmember Support Nuts ................................................................................................................................... 53-72 Nm (39-53 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Skid Plate > Component Information > Specifications Skid Plate: Specifications TORQUE SPECIFICATIONS Skid Plate Bolts ................................................................................................................................... ....................................... 14-17 Nm (11-12 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement Technical Service Bulletin # 00S05 Date: 000501 Recall - Trailer Hitch Hardware Replacement 00S05 SAFETY RECALL All 1997-2000 Model Year Expedition and Navigator with Trailer Hitch Package - Hitch Attachment ^ Original - May, 2000 Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter Customer Notification Letter ^ Supplement # 1 - May, 2000 Aftermarket Hitch Kits and Existing Dealer Stock Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 11177 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 11178 Attachment I OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. NOTE: Navigator owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Lincoln owners, review Attachment IV to familiarize yourself with this special handling procedure. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instruction on page two of Attachment IV. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Only Navigator owners are eligible for rental cars under the provisions of the "Lincoln Commitment Special Handling Procedure" (refer to Attachment IV). Attachment II Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 11179 LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Parts wilt not be direct shipped for this recall. Order your parts requirement through normal order processing channels as shown. MATERIAL ALLOWANCE A material allowance of $5.25 per vehicle is being given to purchase an underbody coating (Super Seal or equivalent product). Claim this allowance by entering the information shown. SPECIAL ORDER INFORMATION DOR/COR number 50161 identifies parts ordered for this campaign through the Recall Hotline (800-325-5621), for the first 30 days. DEALER PRICE For latest prices, refer to: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III AFFECTED VEHICLES: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 11180 CERTAIN 1997 THROUGH 2000 MODEL YEAR EXPEDITION AND NAVIGATOR EQUIPPED WITH FACTORY INSTALLED TRAILER HITCH OVERVIEW This procedure outlines hitch assembly removal, cleaning and reinstallation using updated attaching hardware. NOTE: REMOVING THE FRAME WAX AS OUTLINED IN STEP 5 IS CRITICAL TO THE OVERALL ROBUSTNESS OF THIS REPAIR. SERVICE PROCEDURE 1. Turn off the air suspension switch, then raise and support the vehicle on a hoist. 2. Remove the hitch electrical connector bracket from the hitch assembly. 3. Position two (2) jack stands to support the hitch assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 11181 4. Remove all bolts and nut plates attaching the hitch to the frame, then remove the hitch assembly from the vehicle. See Figures 1 and 2. 5. Using Brake Metal Parts Cleaner (F6AZ-2C410-AB) or equivalent obtained locally, remove the frame wax from all areas where there is hitch- or nut plate-to-frame contact. This includes: ^ the inside areas of the hitch ^ the inside and outside areas of the frame web. ^ the upper and lower areas of the frame flanges. CAUTION To avoid cross threading the bolts into the nut plates, start each bolt by hand and be sure it is threading properly into the nut plate. CAUTION Do not final tighten any bolts until all have been installed. Be sure to tighten the horizontal bolts first (Step 7) before tightening the vertical bolts (Step 8). 6. Reposition the hitch on the jack stands and install the new bolts and new nut plates. Only tighten the bolts snug at this time. 7. Tighten the horizontal attaching bolts to 175 Nm (129 lb-ft). 8. Tighten the vertical attaching bolts to 175 Nm (129 lb-ft). 9. Remove the jack stands. 10. Install the hitch electrical connector bracket. For 7-pin connectors, tighten the bolt to 48 Nm (35 lb-ft). For 4-pin connectors, tighten the bolt to 63 Nm (46 lb-ft). 11. Apply a coat of commercially available underbody anti-corrosion compound meeting Ford specification ESR-M7C54-A to the hitch attachment area ensuring adequate coverage. 12. Lower the vehicle and turn on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 11182 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 11183 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 11184 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 11185 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 11186 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 11187 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 11188 Supplement # 1 - Attachment I OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT (I )Immediately contact any affected owner whose name is not on the list Give the owner a copy of the Owner Letter and schedule a service date. This contact includes owners who have purchased aftermarket hitch kit # F75Z-17D826-AE. NOTE: Navigator owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Lincoln owners, review Attachment IV to familiarize yourself with this special handling procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 11189 REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instructions on page two of Attachment IV. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Only Navigator owners are eligible for rental cars under the provisions of the "Lincoln Commitment Special Handling Procedure" (refer to Attachment IV). Supplement # 1 - Attachment II LABOR ALLOWANCES PARTS REQUIREMENTS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 11190 Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channels as shown above. MATERIAL ALLOWANCE A material allowance of $5.25 per vehicle is being given to purchase an underbody coating (Super Seal or equivalent product). Claim this allowance by entering the information above: SPECIAL ORDER INFORMATION DOR/COR number 50161 identifies parts ordered for this campaign through the Recall Hotline (800-325-5621), for the first 30 days. (I )REWORK OF EXISTING DEALER STOCK Call the Recall Hotline at 1-800-325-5621,to obtain instructions for reworking existing stock of Trailer Hitch Kits (part # F75Z-17D826-AE). NOTE: The Recall Hotline will provide new hardware and kit installation instructions.When you rework dealer stock, please make sure these revised instructions (with new torque specifications) are included in the kit. DEALER PRICE For latest prices, refer to: ^ DOESII ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Supplement # 1 - Attachment III HITCH ATTACHING FASTENER REPLACEMENT AFFECTED VEHICLES: CERTAIN 1997 THROUGH 2000 MODEL YEAR EXPEDITION AND NAVIGATOR EQUIPPED WITH FACTORY INSTALLED TRAILER HITCH OVERVIEW This procedure outlines hitch assembly removal, cleaning and reinstallation using updated attaching hardware. NOTE: REMOVING THE FRAME WAX AS OUTLINED IN STEP 5 IS CRITICAL TO THE OVERALL ROBUSTNESS OF THIS REPAIR. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 11191 SERVICE PROCEDURE 1. Turn off the air suspension switch, then raise and support the vehicle on a hoist. 2. Remove the hitch electrical connector bracket from the hitch assembly. 3. Position two (2) jack stands to support the hitch assembly. 4. Remove all bolts and nut plates attaching the hitch to the frame, then remove the hitch assembly from the vehicle. See Figures 1 and 2. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 11192 5. Using Brake Metal Parts Cleaner (F6AZ-2C410-AB) or equivalent obtained locally, remove the frame wax from all areas where there is hitch- or nut plate-to-frame contact. This includes: ^ the inside areas of the hitch. ^ the inside and outside areas of the frame web. ^ the upper and lower areas of the frame flanges. CAUTION To avoid cross threading the bolts into the nut plates, start each bolt by hand and be sure it is threading properly into the nut plate. CAUTION Do not final tighten any bolts until all have been installed. Be sure to tighten the horizontal bolts first (Step 7) before tightening the vertical bolts (Step 8). 6. Reposition the hitch on the jack stands and install the new bolts and new nut plates. Only tighten the bolts snug at this time. 7. Tighten the horizontal attaching bolts to 175 Nm (129 lb-ft). 8. Tighten the vertical attaching bolts to 175 Nm (129 lb-ft). 9. Remove the jack stands. 10. Install the hitch electrical connector bracket. For 7-pin connectors, tighten the bolt to 48 Nm (35 lb-ft). For 4-pin connectors, tighten the bolt to 63 Nm (46 lb-ft). 11. Apply a coat of commercially available underbody anti-corrosion compound meeting Ford specification ESR-M7C54-A to the hitch attachment area ensuring adequate coverage. 12. Lower the vehicle and turn on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 11193 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 11194 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 11195 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 11196 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > NHTSA00V073000 > Mar > 00 > Recall 00V073000: Trailer Hitch Attaching Bolts Loose Trailer Hitch: Recalls Recall 00V073000: Trailer Hitch Attaching Bolts Loose Vehicle Description: Multi-purpose vehicles. The trailer hitch assembly to the frame attaching bolts could lose the clamp load. The trailer hitch could then separate from the vehicle. Dealers will replace the trailer hitch mounting bolts and nut plates. Owner notification began May 15, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1997 FORD TRUCK EXPEDITION 1997 LINCOLN TRUCK NAVIGATOR 1998 FORD TRUCK EXPEDITION 1998 LINCOLN TRUCK NAVIGATOR 1999 FORD TRUCK EXPEDITION 1999 LINCOLN TRUCK NAVIGATOR 2000 FORD TRUCK EXPEDITION 2000 LINCOLN TRUCK NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement Technical Service Bulletin # 00S05 Date: 000501 Recall - Trailer Hitch Hardware Replacement 00S05 SAFETY RECALL All 1997-2000 Model Year Expedition and Navigator with Trailer Hitch Package - Hitch Attachment ^ Original - May, 2000 Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter Customer Notification Letter ^ Supplement # 1 - May, 2000 Aftermarket Hitch Kits and Existing Dealer Stock Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 11206 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 11207 Attachment I OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. NOTE: Navigator owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Lincoln owners, review Attachment IV to familiarize yourself with this special handling procedure. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instruction on page two of Attachment IV. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Only Navigator owners are eligible for rental cars under the provisions of the "Lincoln Commitment Special Handling Procedure" (refer to Attachment IV). Attachment II Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 11208 LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Parts wilt not be direct shipped for this recall. Order your parts requirement through normal order processing channels as shown. MATERIAL ALLOWANCE A material allowance of $5.25 per vehicle is being given to purchase an underbody coating (Super Seal or equivalent product). Claim this allowance by entering the information shown. SPECIAL ORDER INFORMATION DOR/COR number 50161 identifies parts ordered for this campaign through the Recall Hotline (800-325-5621), for the first 30 days. DEALER PRICE For latest prices, refer to: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III AFFECTED VEHICLES: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 11209 CERTAIN 1997 THROUGH 2000 MODEL YEAR EXPEDITION AND NAVIGATOR EQUIPPED WITH FACTORY INSTALLED TRAILER HITCH OVERVIEW This procedure outlines hitch assembly removal, cleaning and reinstallation using updated attaching hardware. NOTE: REMOVING THE FRAME WAX AS OUTLINED IN STEP 5 IS CRITICAL TO THE OVERALL ROBUSTNESS OF THIS REPAIR. SERVICE PROCEDURE 1. Turn off the air suspension switch, then raise and support the vehicle on a hoist. 2. Remove the hitch electrical connector bracket from the hitch assembly. 3. Position two (2) jack stands to support the hitch assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 11210 4. Remove all bolts and nut plates attaching the hitch to the frame, then remove the hitch assembly from the vehicle. See Figures 1 and 2. 5. Using Brake Metal Parts Cleaner (F6AZ-2C410-AB) or equivalent obtained locally, remove the frame wax from all areas where there is hitch- or nut plate-to-frame contact. This includes: ^ the inside areas of the hitch ^ the inside and outside areas of the frame web. ^ the upper and lower areas of the frame flanges. CAUTION To avoid cross threading the bolts into the nut plates, start each bolt by hand and be sure it is threading properly into the nut plate. CAUTION Do not final tighten any bolts until all have been installed. Be sure to tighten the horizontal bolts first (Step 7) before tightening the vertical bolts (Step 8). 6. Reposition the hitch on the jack stands and install the new bolts and new nut plates. Only tighten the bolts snug at this time. 7. Tighten the horizontal attaching bolts to 175 Nm (129 lb-ft). 8. Tighten the vertical attaching bolts to 175 Nm (129 lb-ft). 9. Remove the jack stands. 10. Install the hitch electrical connector bracket. For 7-pin connectors, tighten the bolt to 48 Nm (35 lb-ft). For 4-pin connectors, tighten the bolt to 63 Nm (46 lb-ft). 11. Apply a coat of commercially available underbody anti-corrosion compound meeting Ford specification ESR-M7C54-A to the hitch attachment area ensuring adequate coverage. 12. Lower the vehicle and turn on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 11211 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 11212 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 11213 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 11214 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 11215 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 11216 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 11217 Supplement # 1 - Attachment I OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT (I )Immediately contact any affected owner whose name is not on the list Give the owner a copy of the Owner Letter and schedule a service date. This contact includes owners who have purchased aftermarket hitch kit # F75Z-17D826-AE. NOTE: Navigator owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Lincoln owners, review Attachment IV to familiarize yourself with this special handling procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 11218 REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instructions on page two of Attachment IV. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Only Navigator owners are eligible for rental cars under the provisions of the "Lincoln Commitment Special Handling Procedure" (refer to Attachment IV). Supplement # 1 - Attachment II LABOR ALLOWANCES PARTS REQUIREMENTS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 11219 Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channels as shown above. MATERIAL ALLOWANCE A material allowance of $5.25 per vehicle is being given to purchase an underbody coating (Super Seal or equivalent product). Claim this allowance by entering the information above: SPECIAL ORDER INFORMATION DOR/COR number 50161 identifies parts ordered for this campaign through the Recall Hotline (800-325-5621), for the first 30 days. (I )REWORK OF EXISTING DEALER STOCK Call the Recall Hotline at 1-800-325-5621,to obtain instructions for reworking existing stock of Trailer Hitch Kits (part # F75Z-17D826-AE). NOTE: The Recall Hotline will provide new hardware and kit installation instructions.When you rework dealer stock, please make sure these revised instructions (with new torque specifications) are included in the kit. DEALER PRICE For latest prices, refer to: ^ DOESII ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Supplement # 1 - Attachment III HITCH ATTACHING FASTENER REPLACEMENT AFFECTED VEHICLES: CERTAIN 1997 THROUGH 2000 MODEL YEAR EXPEDITION AND NAVIGATOR EQUIPPED WITH FACTORY INSTALLED TRAILER HITCH OVERVIEW This procedure outlines hitch assembly removal, cleaning and reinstallation using updated attaching hardware. NOTE: REMOVING THE FRAME WAX AS OUTLINED IN STEP 5 IS CRITICAL TO THE OVERALL ROBUSTNESS OF THIS REPAIR. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 11220 SERVICE PROCEDURE 1. Turn off the air suspension switch, then raise and support the vehicle on a hoist. 2. Remove the hitch electrical connector bracket from the hitch assembly. 3. Position two (2) jack stands to support the hitch assembly. 4. Remove all bolts and nut plates attaching the hitch to the frame, then remove the hitch assembly from the vehicle. See Figures 1 and 2. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 11221 5. Using Brake Metal Parts Cleaner (F6AZ-2C410-AB) or equivalent obtained locally, remove the frame wax from all areas where there is hitch- or nut plate-to-frame contact. This includes: ^ the inside areas of the hitch. ^ the inside and outside areas of the frame web. ^ the upper and lower areas of the frame flanges. CAUTION To avoid cross threading the bolts into the nut plates, start each bolt by hand and be sure it is threading properly into the nut plate. CAUTION Do not final tighten any bolts until all have been installed. Be sure to tighten the horizontal bolts first (Step 7) before tightening the vertical bolts (Step 8). 6. Reposition the hitch on the jack stands and install the new bolts and new nut plates. Only tighten the bolts snug at this time. 7. Tighten the horizontal attaching bolts to 175 Nm (129 lb-ft). 8. Tighten the vertical attaching bolts to 175 Nm (129 lb-ft). 9. Remove the jack stands. 10. Install the hitch electrical connector bracket. For 7-pin connectors, tighten the bolt to 48 Nm (35 lb-ft). For 4-pin connectors, tighten the bolt to 63 Nm (46 lb-ft). 11. Apply a coat of commercially available underbody anti-corrosion compound meeting Ford specification ESR-M7C54-A to the hitch attachment area ensuring adequate coverage. 12. Lower the vehicle and turn on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 11222 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 11223 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 11224 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 11225 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > NHTSA00V073000 > Mar > 00 > Recall 00V073000: Trailer Hitch Attaching Bolts Loose Trailer Hitch: All Technical Service Bulletins Recall 00V073000: Trailer Hitch Attaching Bolts Loose Vehicle Description: Multi-purpose vehicles. The trailer hitch assembly to the frame attaching bolts could lose the clamp load. The trailer hitch could then separate from the vehicle. Dealers will replace the trailer hitch mounting bolts and nut plates. Owner notification began May 15, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1997 FORD TRUCK EXPEDITION 1997 LINCOLN TRUCK NAVIGATOR 1998 FORD TRUCK EXPEDITION 1998 LINCOLN TRUCK NAVIGATOR 1999 FORD TRUCK EXPEDITION 1999 LINCOLN TRUCK NAVIGATOR 2000 FORD TRUCK EXPEDITION 2000 LINCOLN TRUCK NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Specifications Arm Rest: Specifications Captain's Chair Armrest Bolt ............................................................................................................................................................. 44-55 Nm (33-40 ft lb) Front Seat Center Armrest Bolts ........................................................................................................................................................ 44-55 Nm (33-40 ft lb) Front Seat Center Armrest Latch Bolts .............................................................................................................................................. 44-55 Nm (33-40 ft lb) Front Seat Center Armrest Mounting Bracket Bolts .......................................................................................................................... 44-55 Nm (33-40 ft lb) Front Seat Armrest Shield Screws ........................................................................................................................................................... 1-3 Nm (9-26 in lb) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Specifications > Page 11234 Arm Rest: Service and Repair ARMREST - CAPTAIN'S CHAIR REMOVAL 1. Unwrap the armrest cover bungee cord to access the armrest bolt. 2. Remove the armrest bolt and spring washer. INSTALLATION 1. To install, reverse the removal procedure. ^ Check for proper operation. NOTE: Install new spring washer. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest for Console: > 97-12-10 > Jun > 97 > Blower Motor - Vibration/Noise from Center Console Console: Customer Interest Blower Motor - Vibration/Noise from Center Console Article No. 97-12-10 06/09/97 ^ BLOWER MOTOR - VIBRATION OR "FLUTTERING" NOISE COMING FROM CENTER CONSOLE ^ NOISE - VIBRATION OR "FLUTTERING" NOISE FROM CENTER CONSOLE WITH BLOWER MOTOR OPERATING LIGHT TRUCK: 1997 EXPEDITION ISSUE: A vibration or "fluttering" noise coming from the center console when the blower motor is operating may be heard on some vehicles. This may be due to a blower motor assembly imbalance. ACTION: Replace the blower motor/wheelhousing assembly. The new blower assembly is balanced at the factory. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify concern. 2. Remove the floor console. Refer to the 1997 Expedition Workshop Manual, Section 501-12 for details. 3. Remove the eight (8) screws from the floor console support braces. Remove the braces. Refer to Figure 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest for Console: > 97-12-10 > Jun > 97 > Blower Motor - Vibration/Noise from Center Console > Page 11243 4. Remove the two (2) screws from the blower motor duct. Remove the duct. Refer to Figure 2. 5. Remove the three (3) blower motor assembly nuts. Remove the blower assembly. Refer to Figure 3. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest for Console: > 97-12-10 > Jun > 97 > Blower Motor - Vibration/Noise from Center Console > Page 11244 6. Disconnect the electrical connectors. Refer to Figure 4. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest for Console: > 97-12-10 > Jun > 97 > Blower Motor - Vibration/Noise from Center Console > Page 11245 7. Replace the assembly with a revised Center Console Blower Motor Assembly (F77Z-18456-BA) by reversing Steps 2-6. Refer to Figures 5-7. 8. Verify repair. PART NUMBER PART NAME F77Z-18456-BA Center Console Blower Assembly OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971210A Replace Blower Motor 0.8 Hr. Wheelhousing Assembly DEALER CODING CONDITION BASIC PART NO. CODE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest for Console: > 97-12-10 > Jun > 97 > Blower Motor - Vibration/Noise from Center Console > Page 11246 18456 12 OASIS CODES: 208000, 208999, 702000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 97-12-10 > Jun > 97 > Blower Motor - Vibration/Noise from Center Console Console: All Technical Service Bulletins Blower Motor - Vibration/Noise from Center Console Article No. 97-12-10 06/09/97 ^ BLOWER MOTOR - VIBRATION OR "FLUTTERING" NOISE COMING FROM CENTER CONSOLE ^ NOISE - VIBRATION OR "FLUTTERING" NOISE FROM CENTER CONSOLE WITH BLOWER MOTOR OPERATING LIGHT TRUCK: 1997 EXPEDITION ISSUE: A vibration or "fluttering" noise coming from the center console when the blower motor is operating may be heard on some vehicles. This may be due to a blower motor assembly imbalance. ACTION: Replace the blower motor/wheelhousing assembly. The new blower assembly is balanced at the factory. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify concern. 2. Remove the floor console. Refer to the 1997 Expedition Workshop Manual, Section 501-12 for details. 3. Remove the eight (8) screws from the floor console support braces. Remove the braces. Refer to Figure 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 97-12-10 > Jun > 97 > Blower Motor - Vibration/Noise from Center Console > Page 11252 4. Remove the two (2) screws from the blower motor duct. Remove the duct. Refer to Figure 2. 5. Remove the three (3) blower motor assembly nuts. Remove the blower assembly. Refer to Figure 3. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 97-12-10 > Jun > 97 > Blower Motor - Vibration/Noise from Center Console > Page 11253 6. Disconnect the electrical connectors. Refer to Figure 4. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 97-12-10 > Jun > 97 > Blower Motor - Vibration/Noise from Center Console > Page 11254 7. Replace the assembly with a revised Center Console Blower Motor Assembly (F77Z-18456-BA) by reversing Steps 2-6. Refer to Figures 5-7. 8. Verify repair. PART NUMBER PART NAME F77Z-18456-BA Center Console Blower Assembly OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971210A Replace Blower Motor 0.8 Hr. Wheelhousing Assembly DEALER CODING CONDITION BASIC PART NO. CODE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 97-12-10 > Jun > 97 > Blower Motor - Vibration/Noise from Center Console > Page 11255 18456 12 OASIS CODES: 208000, 208999, 702000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Page 11256 Console: Specifications Rear Console Bolts .............................................................................................................................. ..................................... 10.2-13.8 Nm (91-122 in lb) Rear Console Tray Screws .............................................................................................................................................................. 2.1-2.9 Nm (19-25 in lb) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Page 11257 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console-Overhead Console: Service and Repair Console-Overhead REMOVAL 1. Open the overhead sunglasses compartment and remove the screw. 2. Grasp the front of the overhead console, pull down and remove the console. 3. Disconnect the electrical connectors. 4. Remove the trip computer. 1. Depress the lock tab underneath the in-line electrical connector. 2. Remove the in-line connector. 3. Remove the screws. 4. Remove the trip computer. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console-Overhead > Page 11260 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console-Overhead > Page 11261 Console: Service and Repair Floor Console REMOVAL 1. Disconnect the battery ground cable. 2. Remove the console tray mat. 3. Remove the console tray front screw. 4. Remove the console tray rear screw. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console-Overhead > Page 11262 5. Remove the console tray. 6. Remove the center console front bolts. 7. Disconnect the center console electrical connector. 8. Remove the two rear center console bolt covers. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console-Overhead > Page 11263 9. Remove the two rear console bolts. 10. Remove the center console. ^ Lift the front of the console and slide rearward to disengage floor brackets. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console-Overhead > Page 11264 INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming Deactivation Procedure 1. Disconnect positive battery cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Wait one minute. This is the time required for backup power supply in air bag diagnostic monitor to deplete its stored energy. 3. Remove two back cover plugs and remove screw and washer assemblies retaining driver side air bag module to steering wheel. Disconnect horn electrical connector. Disconnect driver air bag sliding contact electrical connector. Remove driver side air bag module from vehicle. WARNING: Place air bag module on bench with trim cover facing up. 4. Connect Rotunda Air Bag Simulator 105-R0011 or equivalent to vehicle harness at top of steering column. 5. Remove passenger side air bag module. Install Rotunda Air Bag Simulator 105-00012 or equivalent on vehicle harness connector in place of passenger side air bag module. 6. Reconnect positive battery cable. Reactivation Procedure 1. Disconnect positive battery cable. WARNING: The air bag simulator must be removed and the air bag reconnected when the system is reactivated. 2. Wait one minute for backup power supply in air bag diagnostic monitor to deplete stored energy. 3. Remove air bag simulator from vehicle harness connector at top of steering column. 4. Reconnect driver side air bag module. 5. Position driver side air bag module on steering wheel and secure with two screw and washer assemblies (8 mm). Tighten screw and washer assemblies to 10-13 Nm (89-115 lb in). Install two back cover plugs. 6. Remove air bag simulator from vehicle harness connector on passenger side. Reconnect and install passenger side air bag module. 7. Reconnect positive battery cable. 8. Prove out system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 11270 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The check list below should be completed following diagnosis or service of any air bag system concern: 1. Are both air bag crash sensors connected and mounted to the vehicle? 2. Is 3-way connector at base of steering column connected? 3. Are the air bags or air bag simulators connected? 4. Is air bag diagnostic monitor connected? 5. Is vehicle battery connected? Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Liftgate Trim Panel Trim Panel: Service and Repair Liftgate Trim Panel REMOVAL 1. Remove the upper liftgate trim panel. 2. Remove the liftgate assist strap. 1 Remove the screws. 2 Remove the liftgate assist strap. 3. Remove the lower lift gate trim panel. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Liftgate Trim Panel > Page 11275 Trim Panel: Service and Repair Quarter Trim Panel Safety Belt Bolt Bit SPECIAL TOOL(S) REMOVAL 1. Remove the liftgate door opening weather seal. 2. Remove the liftgate scuff plate. 3. If equipped, remove the third row seat. 4. Remove the rear header garnish trim panel. 5. Remove the rear door scuff plates. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Liftgate Trim Panel > Page 11276 6. Fold down the second row seat. 7. Remove the cross car scuff plate. 8. Remove the second row safety belt guide nut. 1 Lift the cover. 2 Remove the nut. 9. Remove the second row safety belt lower nut. 10. Remove the C-pillar trim panel. ^ Remove the rear door opening weather seal. ^ Remove the C-pillar trim panel. NOTE: Remove the upper attachments followed by the lower attachment and the lower rear hook. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Liftgate Trim Panel > Page 11277 11. If equipped, remove the third row safety belt guide. 1 Lift the cover. 2 Use Safety Belt Bolt Bit to remove the safety belt guide bolt. 3 Remove the third row safety belt guide. 12. Remove the D-pillar trim panel. ^ Remove the liftgate door opening weather seal. NOTE: Remove the lower hook attached to the quarter trim panel, followed by the top attachment, and then the lower rear attachment. 13. Remove the quarter trim panel. 1 Remove the screws and pin-type retainer. 2 Remove the quarter trim panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Liftgate Trim Panel > Page 11278 INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Door Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 11285 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 11286 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 11287 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 11288 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 11289 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Specifications Keyless Entry Module: Specifications RAP Module Nuts ................................................................................................................................ ...................................................... 7 Nm (62.4 in lb) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Specifications > Page 11294 Keyless Entry Module: Locations Body Views Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Specifications > Page 11295 The Remote Anti-Theft Personality Module is located behind left side of instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Specifications > Page 11296 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect the C257 and C256 Remote Anti-theft Personality (RAP) module electrical connectors. 2. Disconnect the antenna connector. 3. Remove the RAP module nuts and the RAP module. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Description and Operation Keyless Entry Transmitter: Description and Operation NOTE: The remote entry features will not function when the ignition switch is in the RUN or ACC position. The keyless entry remote transmitters: ^ Are reprogrammable. ^ Must be set at the same time. To unlock the driver door: ^ Press the UNLOCK button on the keyless entry remote transmitter. NOTE: If more than five seconds have elapsed since the first press of the UNLOCK button, pressing the UNLOCK button again will only unlock the driver door a second time. To unlock all doors: ^ Press the UNLOCK button on the keyless entry remote transmitter a second time, within five seconds of the first unlock. To lock all doors: ^ Press the LOCK button on the keyless entry remote transmitter once. ^ Press the LOCK button again, within five seconds of the first press. The horn will chirp once if the doors have locked and all doors are closed. The horn will chirp twice if a door is open, indicating that the anti-theft system will not arm until all the doors are closed. To confirm that the doors have been locked: ^ Press the LOCK button again, within five seconds of the first press. The horn will chirp once. To activate the panic alarm: ^ Press the red PANIC button on the keyless entry remote transmitter. The horn will sound and the headlamps and exterior lamps will flash for a maximum of two minutes and 45 seconds. To deactivate the panic alarm: ^ Press the red PANIC button again on the keyless entry remote transmitter. ^ Turn the ignition switch to RUN/ACC. Inputs and Outputs The RAP module receives input from the following components for electronic door lock system operation: ^ Keyless entry remote transmitters. ^ Door ajar output from the GEM. ^ Brake on/off switch. ^ Transmission range (TR) sensor. ^ Remote entry antenna. The RAP module distributes output to the following for the electronic door lock system: ^ Driver unlock relay. ^ All unlock relay. ^ All lock relay. ^ Horn relay. ^ Headlamp relay. ^ Park lamp relay. ^ Illuminated entry request output to the GEM. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Description and Operation > Page 11300 Keyless Entry Transmitter: Service and Repair NOTE: All keyless entry remote transmitters must be set at the same time. To program (or reprogram) the keyless entry remote transmitters into the RAP module, perform the following steps: 1. Turn the ignition switch from OFF to RUN five times within ten seconds, ending in RUN. If the RAP module has successfully entered program mode, it will lock and then unlock all doors. 2. Press any button on a keyless entry remote transmitter, and the doors will lock and then unlock to confirm that each keyless entry remote transmitter has been programmed. 3. If the door locks do not respond for any keyless entry remote transmitter, wait several seconds and press the button again. If the door locks still fail to respond, refer to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures 4. Turn the ignition switch to the OFF position, or wait up to five minutes after step 2, to exit program mode. If a keyless entry remote transmitter has been programmed (or reprogrammed), the RAP module will lock and unlock all doors one last time to confirm. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > All Lock Relay Power Door Lock Relay: Locations All Lock Relay Body View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 11306 Lock Relays The All Lock Relay is located in lock relays. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 11307 Power Door Lock Relay: Locations All Unlock Relay Body View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 11308 Lock Relays The All Lock Relay is located in lock relays. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 11309 Power Door Lock Relay: Locations Driver's Door Unlock Relay Body View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 11310 Lock Relays The Driver's Unlock Relay is located in lock relays. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 11311 Power Door Lock Relay: Locations Lock Relays Body View The Lock Relays are located behind right side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Left Door Left Power Door Lock Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Left Door > Page 11316 Right Power Door Lock Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Trunk / Liftgate Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 11321 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 11322 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 11323 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 11324 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 11325 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions Heated Element: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 11331 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 11332 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 11333 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 11334 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 11335 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 11336 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 11337 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 11338 Heated Element: Connector Views Left Power/Heated/Signal Mirror Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 11339 Right Power/Heated/Signal Mirror Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 11340 Rear Window Defrost/Mirror Defrost Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Page 11341 Heated Element: Description and Operation The Generic Electronic Module (GEM) controls the heated backlight grid and heated mirrors by controlling the state of the heated backlight/mirror relay. When the heated backlight/mirror switch is pressed, the GEM will activate the heated backlight/mirror relay. When the heated backlight/mirror relay is active, both the heated backlight grid and heated mirror elements will be energized. The GEM will deactivate the heated backlight/mirror relay when one of the following conditions is met: ^ The heated backlight/mirror switch is pressed when the feature is active. ^ Ignition switch state is changed from RUN to OFF/LOCK. ^ The 10 minute timing function is completed. Feature Inputs: ^ Ignition switch RUN position (12V on both RUN and RUN/ACC inputs). ^ Heated backlight/mirror switch (momentary contact to ground when switch is pressed). Feature Outputs: ^ Heated backlight/mirror relay control (grounded when activated, open circuit when deactivated). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Mirror Relay > Component Information > Locations Heated Mirror Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Mirror Relay > Component Information > Locations > Page 11345 Junction Box Fuse/Relay Panel (Part 1 Of 2) The Heated Grid Relay is located in junction box fuse/relay panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams Power Mirror Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 99-12-10 > Jun > 99 > Paint - Rough Texture Technical Service Bulletin # 99-12-10 Date: 990614 Paint - Rough Texture Article No. 99-12-10 06/14/99 ^ PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN NEUTRALIZATION ^ PAINT - ROUGH TEXTURE/FERROUS METAL CONTAMINATION - ACID RAIN DISCOLORATION OR ETCHING FORD: 1996-1997 ASPIRE, PROBE, THUNDERBIRD 1996-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1996-1997 COUGAR 1996-1998 MARK VIII 1996-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR LIGHT TRUCK: 1996 BRONCO 1996-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1996-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1996-1997 CARGO SERIES 1996-1998 AEROMAX, F SERIES, LOUISVILLE This TSB article is being republished in its entirety to add vehicles and model years, and to revise the procedure to use Ford brand service parts. ISSUE Ford Motor Company has released a private labeled material to be used for iron particle/acid rain service repairs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 11358 ACTION To remove these particles/contaminates, use ONLY the following products and procedure. No polishing, compounding, color sanding, or repainting should be done before this procedure is performed. This procedure uses products that are acidic, alkaline, and neutral and must be properly mixed and used in their specific order. Refer to the following Service Procedure for details. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 11359 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-21-3 WARRANTY STATUS: Eligible Under The Provisions Of 12 Month/12,000 Mile Basic Warranty Coverage OPERATION DESCRIPTION TIME 991210A Decontaminate And 0.6 Hr. Surface Correction (Aspire, F-450/550, And Cargo) 991210B Decontaminate And 0.7 Hr. Surface Correction (Escort ZX2, Ranger Regular Cab, Probe, Bronco, And Aerostar) 991210C Decontaminate And 0.8 Hr. Surface Correct (Escort/Tracer, Escort/Tracer Wagon, Contour/Mystique, Mustang Convertible/Convertible OT, Taurus/Sable Sedan Or Wagon, 1996-1998 Villager, And 1999 Cougar) 991210D Decontaminate And 0.8 Hr. Surface Correction (F-Series And 1996-97 Thunderbird/Cougar) 991210E Decontaminate And 0.8 Hr. Surface Correction (Ranger SuperCab/Splash, F-150/250 6Ft Bed - Regular Cab/Flare Side Regular Cab, F-250/350 SD 6Ft Bed - Regular Cab, F-450/550 Crew Cab, And Louisville/AeroMax) 991210F Decontaminate And 0.9 Hr. Surface Correction (Mustang Coupe/Coupe GT, Continental, Mark VIII, Ranger Splash SuperCab, Explorer 2-Door, And 1999 Villager) 991210G Decontaminate And 0.9 Hr. Surface Correction (F-150/250 6Ft Bed - SuperCab/8Ft Bed - Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 11360 Regular Cab/Flare Side - SuperCab, And F-250/350 SD 6Ff Bed - SuperCab/8Ft Bed - Regular Cab) 991210H Decontaminate And 1.0 Hr. Surface Correction (Crown Victoria/Grand Marquis, Town Car, Windstar, Explorer 4-Door, And Mountaineer) 9912101 Decontaminate And 1.0 Hr. Surface Correction (F-150/250 8Ft Bed - SuperCab, F-250/350 SD 6Ft Bed - Crew Cab/8Ft Bed SuperCab/8Ft Bed - Crew Cab, And Expedition/Navigator) 991210J Decontaminate And 1.2 Hrs. Surface Correction (Econoline Wagon/Wagon Super-V) 991210k Decontaminate And 1.3 Hrs. Surface Correction (Econoline Cargo) 991210L Decontaminate And 1.4 Hrs. Surface Correction (Econoline Cargo Super-V) DEALER CODING CONDITION BASIC PART NO. CODE ENTRE C8 OASIS CODES: 106000,190000 Service Procedure NOTE ANY CHANGES TO THIS PROCEDURE WILL CAUSE AN INCOMPLETE OR UNSATISFACTORY REPAIR. THE USE OF ANY OTHER PRODUCT OR PROCEDURE MAY CAUSE DAMAGE TO ALUMINUM OR PAINTED SURFACES. NOTE THE PRODUCTS USED TO REMOVE SURFACE CONTAMINATION FROM PAINT ARE DESIGNED FOR VEHICLES WHICH HAVE EXPERIENCED EXPOSURE FOR LESS THAN 120 DAYS. VEHICLES THAT EXCEED 120 DAYS OF EXPOSURE MAY REQUIRE THE PROCEDURE BE REPEATED TO RESOLVE THE CONCERN. ONCE THIS PROCEDURE IS COMPLETED, IT MAY BE NECESSARY TO PERFORM POLISHING OR REFINISHING PROCEDURES AFTER VEHICLE INSPECTION. Identification Ferrous metal particles (hot iron dust) are generated by manufacturing facilities, rail shipments, etc. These particles mechanically bond to a vehicle's painted surfaces. Moisture and temperature combine with particles to create a chemical reaction. This reaction creates an acid, causing the iron to corrode and enter the paint surface. Industrial fallout and acid rain generate corrosive compounds that fall on the vehicle's painted surfaces. When subjected to moisture and temperature, chemical compounds are created that etch the paint surface. To assist in identitying surface contamination, use a (Tandy-Radio Shack # 63-851) 30x lighted magnifier. Concern Description Ferrous Metal Light Colored Vehicles: Small orange stains the size of "mechanical pencil lead." The surface is rough to the touch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 11361 Dark Colored Vehicles: Small white or silver appearing dots with a rainbow ring around the dot. The surface is rough to the touch. Industrial Fallout Water spots with ferrous metal are present and the surface is rough to the touch. Acid Rain/Etching ^ Surface will exhibit irregular discolored spotting. ^ Dark colored vehicles may exhibit cloudy or graying spots where the acid has begun to etch the paint. ^ Extreme cases of etching will be visible and may be felt. Decontamination Procedure Use Ford Acid Neutralizer, Alkaline Neutralizer, and Detail Wash to decontaminate and neutralize the paint surface. Perform the procedure only on vehicle when the paint surface temperature is cool. Follow the step-by-step procedure listed below to perform this service operation. 1. Rinse off dust, dirt, and debris with cold water. Flush liberally. 2. Prepare Acid Neutralizer by mixing 8 parts of water to 1 part Acid Neutralizer in a bucket. 3. Use a clean wash mitt and apply mixture of Acid Neutralizer to the entire vehicle starting at the top of the vehicle working toward the side. Keep the vehicle wet with solution, lightly agitating for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. NOTE USE A SEPARATE MITT FOR EACH PRODUCT. DO NOT INTERMIX MITTS. 4. Rinse the vehicle thoroughly with cold water to remove Acid Neutralizer. 5. Dry only the horizontal surfaces of the vehicle at this time. Do not dry glass. 6. Alkaline Neutralizer is ready to use. Do not mix with water. Pour the contents into a dispenser squirt bottle. Squirt Alkaline Neutralizer directly onto a clean wash mitt. Do not spray Alkaline Neutralizer on the painted surface. Apply the product to the vehicle, keeping the areas wet and lightly agitated for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. 7. Rinse the vehicle thoroughly with cold water. 8. Prepare Detail Wash by mixing 29.5 mL (1 ounce) of Detail Wash to 3.7L (1 gallon) of water. 9. Shampoo the vehicle with Detail Wash using a clean wash mitt. Rinse the vehicle with cold water and dry the vehicle completely. NOTE DETAIL WASH IS A HEAVY DUTY NEUTRAL SHAMPOO CONCENTRATE (pH 7) AND MAY BE USED FOR HAND CAR WASHING OR IN AUTOMATIC CAR WASH SYSTEMS. Surface Correction Following Decontam./Neutralization 1. Visually inspect paint surface for evidence of removal of ferrous metal particles and water spots. NOTE ACID RAIN DISCOLORING OR ETCHING WILL REQUIRE ADDITIONAL PROCEDURES DEPENDENT ON DEPTH OF DAMAGE; POLISHING, BUFFING, COLOR SANDING, OR IN EXTREME CASES, REFINISHING. 2. Do Not Intermix Buffing Products. Use only one manufacturer's products. 3. Always follow the manufacturer's product usage sequence. Use the appropriate recommended pad at recommended buffing speeds as specified by the product manufacturer. NOTE WHEN ATTEMPTING TO AFFECT A REPAIR BY BUFFING, POLISHING, OR COLOR SANDING, DO NOT REMOVE AN EXCESS OF 0.3 MIL OF PAINT FILM OR REFINISHING WILL BE REQUIRED. USE OF AN ELECTRONIC MIL GAUGE (ROTUNDA 164-R4025) IS HIGHLY RECOMMENDED TO INSURE CONTROL OF PAINT FILM REMOVAL. 4. Use a dual action sander with a Velcro backing plate and a foam pad to fine polish and remove any swirls created by a rotary buffer or pad. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 11362 5. Use an alcohol and water mixture (1 to 1 ratio) to clean the buffed areas and to verify removal of scratches and swirls before application of the final polish. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture Technical Service Bulletin # 99-12-10 Date: 990614 Paint - Rough Texture Article No. 99-12-10 06/14/99 ^ PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN NEUTRALIZATION ^ PAINT - ROUGH TEXTURE/FERROUS METAL CONTAMINATION - ACID RAIN DISCOLORATION OR ETCHING FORD: 1996-1997 ASPIRE, PROBE, THUNDERBIRD 1996-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1996-1997 COUGAR 1996-1998 MARK VIII 1996-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR LIGHT TRUCK: 1996 BRONCO 1996-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1996-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1996-1997 CARGO SERIES 1996-1998 AEROMAX, F SERIES, LOUISVILLE This TSB article is being republished in its entirety to add vehicles and model years, and to revise the procedure to use Ford brand service parts. ISSUE Ford Motor Company has released a private labeled material to be used for iron particle/acid rain service repairs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 11368 ACTION To remove these particles/contaminates, use ONLY the following products and procedure. No polishing, compounding, color sanding, or repainting should be done before this procedure is performed. This procedure uses products that are acidic, alkaline, and neutral and must be properly mixed and used in their specific order. Refer to the following Service Procedure for details. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 11369 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-21-3 WARRANTY STATUS: Eligible Under The Provisions Of 12 Month/12,000 Mile Basic Warranty Coverage OPERATION DESCRIPTION TIME 991210A Decontaminate And 0.6 Hr. Surface Correction (Aspire, F-450/550, And Cargo) 991210B Decontaminate And 0.7 Hr. Surface Correction (Escort ZX2, Ranger Regular Cab, Probe, Bronco, And Aerostar) 991210C Decontaminate And 0.8 Hr. Surface Correct (Escort/Tracer, Escort/Tracer Wagon, Contour/Mystique, Mustang Convertible/Convertible OT, Taurus/Sable Sedan Or Wagon, 1996-1998 Villager, And 1999 Cougar) 991210D Decontaminate And 0.8 Hr. Surface Correction (F-Series And 1996-97 Thunderbird/Cougar) 991210E Decontaminate And 0.8 Hr. Surface Correction (Ranger SuperCab/Splash, F-150/250 6Ft Bed - Regular Cab/Flare Side Regular Cab, F-250/350 SD 6Ft Bed - Regular Cab, F-450/550 Crew Cab, And Louisville/AeroMax) 991210F Decontaminate And 0.9 Hr. Surface Correction (Mustang Coupe/Coupe GT, Continental, Mark VIII, Ranger Splash SuperCab, Explorer 2-Door, And 1999 Villager) 991210G Decontaminate And 0.9 Hr. Surface Correction (F-150/250 6Ft Bed - SuperCab/8Ft Bed - Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 11370 Regular Cab/Flare Side - SuperCab, And F-250/350 SD 6Ff Bed - SuperCab/8Ft Bed - Regular Cab) 991210H Decontaminate And 1.0 Hr. Surface Correction (Crown Victoria/Grand Marquis, Town Car, Windstar, Explorer 4-Door, And Mountaineer) 9912101 Decontaminate And 1.0 Hr. Surface Correction (F-150/250 8Ft Bed - SuperCab, F-250/350 SD 6Ft Bed - Crew Cab/8Ft Bed SuperCab/8Ft Bed - Crew Cab, And Expedition/Navigator) 991210J Decontaminate And 1.2 Hrs. Surface Correction (Econoline Wagon/Wagon Super-V) 991210k Decontaminate And 1.3 Hrs. Surface Correction (Econoline Cargo) 991210L Decontaminate And 1.4 Hrs. Surface Correction (Econoline Cargo Super-V) DEALER CODING CONDITION BASIC PART NO. CODE ENTRE C8 OASIS CODES: 106000,190000 Service Procedure NOTE ANY CHANGES TO THIS PROCEDURE WILL CAUSE AN INCOMPLETE OR UNSATISFACTORY REPAIR. THE USE OF ANY OTHER PRODUCT OR PROCEDURE MAY CAUSE DAMAGE TO ALUMINUM OR PAINTED SURFACES. NOTE THE PRODUCTS USED TO REMOVE SURFACE CONTAMINATION FROM PAINT ARE DESIGNED FOR VEHICLES WHICH HAVE EXPERIENCED EXPOSURE FOR LESS THAN 120 DAYS. VEHICLES THAT EXCEED 120 DAYS OF EXPOSURE MAY REQUIRE THE PROCEDURE BE REPEATED TO RESOLVE THE CONCERN. ONCE THIS PROCEDURE IS COMPLETED, IT MAY BE NECESSARY TO PERFORM POLISHING OR REFINISHING PROCEDURES AFTER VEHICLE INSPECTION. Identification Ferrous metal particles (hot iron dust) are generated by manufacturing facilities, rail shipments, etc. These particles mechanically bond to a vehicle's painted surfaces. Moisture and temperature combine with particles to create a chemical reaction. This reaction creates an acid, causing the iron to corrode and enter the paint surface. Industrial fallout and acid rain generate corrosive compounds that fall on the vehicle's painted surfaces. When subjected to moisture and temperature, chemical compounds are created that etch the paint surface. To assist in identitying surface contamination, use a (Tandy-Radio Shack # 63-851) 30x lighted magnifier. Concern Description Ferrous Metal Light Colored Vehicles: Small orange stains the size of "mechanical pencil lead." The surface is rough to the touch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 11371 Dark Colored Vehicles: Small white or silver appearing dots with a rainbow ring around the dot. The surface is rough to the touch. Industrial Fallout Water spots with ferrous metal are present and the surface is rough to the touch. Acid Rain/Etching ^ Surface will exhibit irregular discolored spotting. ^ Dark colored vehicles may exhibit cloudy or graying spots where the acid has begun to etch the paint. ^ Extreme cases of etching will be visible and may be felt. Decontamination Procedure Use Ford Acid Neutralizer, Alkaline Neutralizer, and Detail Wash to decontaminate and neutralize the paint surface. Perform the procedure only on vehicle when the paint surface temperature is cool. Follow the step-by-step procedure listed below to perform this service operation. 1. Rinse off dust, dirt, and debris with cold water. Flush liberally. 2. Prepare Acid Neutralizer by mixing 8 parts of water to 1 part Acid Neutralizer in a bucket. 3. Use a clean wash mitt and apply mixture of Acid Neutralizer to the entire vehicle starting at the top of the vehicle working toward the side. Keep the vehicle wet with solution, lightly agitating for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. NOTE USE A SEPARATE MITT FOR EACH PRODUCT. DO NOT INTERMIX MITTS. 4. Rinse the vehicle thoroughly with cold water to remove Acid Neutralizer. 5. Dry only the horizontal surfaces of the vehicle at this time. Do not dry glass. 6. Alkaline Neutralizer is ready to use. Do not mix with water. Pour the contents into a dispenser squirt bottle. Squirt Alkaline Neutralizer directly onto a clean wash mitt. Do not spray Alkaline Neutralizer on the painted surface. Apply the product to the vehicle, keeping the areas wet and lightly agitated for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. 7. Rinse the vehicle thoroughly with cold water. 8. Prepare Detail Wash by mixing 29.5 mL (1 ounce) of Detail Wash to 3.7L (1 gallon) of water. 9. Shampoo the vehicle with Detail Wash using a clean wash mitt. Rinse the vehicle with cold water and dry the vehicle completely. NOTE DETAIL WASH IS A HEAVY DUTY NEUTRAL SHAMPOO CONCENTRATE (pH 7) AND MAY BE USED FOR HAND CAR WASHING OR IN AUTOMATIC CAR WASH SYSTEMS. Surface Correction Following Decontam./Neutralization 1. Visually inspect paint surface for evidence of removal of ferrous metal particles and water spots. NOTE ACID RAIN DISCOLORING OR ETCHING WILL REQUIRE ADDITIONAL PROCEDURES DEPENDENT ON DEPTH OF DAMAGE; POLISHING, BUFFING, COLOR SANDING, OR IN EXTREME CASES, REFINISHING. 2. Do Not Intermix Buffing Products. Use only one manufacturer's products. 3. Always follow the manufacturer's product usage sequence. Use the appropriate recommended pad at recommended buffing speeds as specified by the product manufacturer. NOTE WHEN ATTEMPTING TO AFFECT A REPAIR BY BUFFING, POLISHING, OR COLOR SANDING, DO NOT REMOVE AN EXCESS OF 0.3 MIL OF PAINT FILM OR REFINISHING WILL BE REQUIRED. USE OF AN ELECTRONIC MIL GAUGE (ROTUNDA 164-R4025) IS HIGHLY RECOMMENDED TO INSURE CONTROL OF PAINT FILM REMOVAL. 4. Use a dual action sander with a Velcro backing plate and a foam pad to fine polish and remove any swirls created by a rotary buffer or pad. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 11372 5. Use an alcohol and water mixture (1 to 1 ratio) to clean the buffed areas and to verify removal of scratches and swirls before application of the final polish. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs Paint: All Technical Service Bulletins Paint - Materials For After Warranty/Warranty Repairs Article No. 98-18-2 09/14/98 PAINT - EXTERIOR - WORLDWIDE RECOMMENDED PAINT MATERIALS FOR WARRANTY AND AFTER WARRANTY REPAIRS FORD: 1997 ASPIRE, PROBE, THUNDERBIRD 1997-98 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1997 COUGAR 1997-98 CONTINENTAL, GRAND MARQUIS, MARK VIII, MYSTIQUE, SABLE, TOWN CAR, TRACER LIGHT TRUCK: 1997 AEROSTAR 1997-98 ECONOLINE, EXPEDITION, EXPLORER, F SUPER DUTY, F-150-350 SERIES, F-47, MOUNTAINEER, RANGER, VILLAGER, WINDSTAR 1998 NAVIGATOR MEDIUM/HEAVY TRUCK: 1997-98 AEROMAX, CARGO SERIES, F & B SERIES, L SERIES, LOUISVILLE This TSB article is being republished in its entirety to add additional paint information. ISSUE Ford Motor Company's goal is to eliminate paint related repeat repairs and increase customer satisfaction. To meet this goal, Ford has tested refinish paint materials that are used for warranty. Tests conducted were designed around OEM Refinish Material Reliability and Durability Standards. ACTION Ford Customer Service Division (FCSD) has released a paint material specification (WSS-M2P100-D) to the major worldwide paint supply companies for testing refinish paint systems. These paint systems are used for refinishing service parts as well as repair steel and plastic OEM finishes. SYSTEMS TESTED Ford Motor Company has completed testing of refinish paint materials that are compliant to U.S. "National Rule," "Canadian Rule" and European VOC (Volatile Organic Compounds) regulations. NOTE TESTING OF CALIFORNIA VOC COMPLIANT SYSTEMS WILL BEGIN 9/98 DUE TO A RECENT MORATORIUM REQUIRING NEW EMISSION COMPLIANT PRODUCTS. SELECTION AND PREPARATION Each paint manufacturer was asked to submit worldwide "in-use" paint systems for testing. The paint materials used for testing were obtained by Ford from local paint jobbers and distributors and/or shipped in from Europe. Employees of each paint company prepared and sprayed the test panels. All testing was completed at the Ford Central Laboratory facility. SUBSTRATES AND TESTS The paint materials approved from these specifications were tested over the following substrates: cold rolled steel, E-coated steel, bare galvanized steel, sanded OEM finish, and TPO plastic. A select group of tests including salt spray, initial adhesion, chipping, fuel resistance, and thermal shock were used for screening. As the companies passed the screening tests, they were required to complete the balance of the tests listed in the specifications. Each panel was tested and reviewed per OEM testing methods. PAINT PRODUCT CHANGES If a paint company decides to introduce a new product into a tested system (i.e., new primer, same clearcoat), the entire system will require retesting. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs > Page 11377 Systems will only be tested once a year. Cost of testing will be the responsibility of the paint suppliers. APPROVED SUPPLIERS AND MATERIALS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs > Page 11378 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs > Page 11379 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs > Page 11380 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs > Page 11381 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs > Page 11382 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs > Page 11383 The Charts following this article (Figures 1-7) indicate paint suppliers and materials. Dealers should begin to use the recommended paint materials as soon as practical. Dealers without a body shop should provide a copy of this bulletin to the independent body shop performing their warranty repairs. The products listed in this bulletin may be made mandatory sometime in the future. As a result, dealers that have jobber/paint company contractual agreements should only contract with recommended suppliers (when existing contracts expire) CONCLUSIONS Testing of refinish materials will raise standards for these materials. These improved standards will result in improved customer satisfaction. OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-18-2 > Sep > 98 > Paint - Materials For After Warranty/Warranty Repairs > Page 11384 SUPERSEDES: 98-9-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000, 190000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-3-3 > Feb > 98 > Paint - Surface Defect Removal Without Repainting Technical Service Bulletin # 98-3-3 Date: 980216 Paint - Surface Defect Removal Without Repainting Article No. 98-3-3 02/16/98 PAINT - SURFACE DEFECT REMOVAL WITHOUT REPAINTING - SERVICE TIP FORD: 1997 ASPIRE, PROBE, THUNDERBIRD 1997-98 CONTOUR 1998 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1997 COUGAR 1997-98 MYSTIQUE 1998 CONTINENTAL, GRAND MARQUIS, MARK VIII, SABLE, TOWN CAR, TRACER LIGHT TRUCK: 1997 AEROSTAR 1997-98 EXPEDITION, EXPLORER, F-150, F-250 LD, F-250 LD, MOUNTAINEER, RANGER, VILLAGER, WINDSTAR 1998 ECONOLINE, NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1997 AEROMAX, CARGO SERIES, F & B SERIES, L SERIES, LOUISVILLE ISSUE: Exterior paint surface maintenance or damage repair where the basecoat does not show through should be restored without repainting. The restoration of gloss and luster may be enhanced with new techniques and three new Ford approved materials. ACTION: The following procedure is applicable to repair surface conditions such as dirt particles, "orange peel," runs, sags, industrial fallout stains, swirl marks, and scratches. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000 Preparation The affected surface must be clean and dry to be repaired. Mask off adjacent panels, mouldings, stripe, and character lines as required. CAUTION: EYE PROTECTION SHOULD BE WORN. JEWELRY, WATCHES, AND BELT BUCKLES MUST BE REMOVED OR COVERED TO PREVENT ACCIDENTAL DAMAGE TO PAINT FINISH. NOTE: CHECK PAINT FILM THICKNESS BEFORE AND AFTER PERFORMANCE OF REPAIRS. MAXIMUM PAINT FILM REMOVAL IS 0.3 OF Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-3-3 > Feb > 98 > Paint - Surface Defect Removal Without Repainting > Page 11389 A MIL. NOTE: PERFORM A TRIAL REPAIR ON A SMALL AREA. FIRST, TRY A POLISH; IF THIS IS NOT SUCCESSFUL, TRY BUFFING WITH FORD MEDIUM DUTY BODY SHOP PAINT CLEANER (F6AZ-19530-BA) OR FORD HEAVY DUTY BODY SHOP PAINT CLEANER (F6AZ-19530-CA) AND, FINALLY, USE WET SANDING TO REMOVE THE CONDITION. USE THE MOST EFFECTIVE TECHNIQUE ON THE REMAINING AREAS. AN OUTLINE OF THE COMPLETE PROCEDURE AND REQUIRED MATERIALS FOLLOWS. Service Notes 1. Remove sanding marks with Ford Medium or Heavy Duty Body Shop Paint Cleaner. 2. Swirl marks, evident after buffing, may be removed by polishing with Ford Light Duty Body Shop Polish (F6AZ-19530-BA). 3. Remove light scratches and small dirt particles with a power buffer and Ford Medium Duty Body Shop Pain Cleaner followed by polishing with Ford Light Duty Body Shop Polish. 4. Remove deep scratches and heavy dirt particles or "orange peel" by wet sanding. Removing Scratches/Swirl Marks/Restore Dull Finish The Black and Decker Buffmaster(R) 5950 is the tool of choice. Variable speed buffers are available in a variety of buffing speeds. The recommended speed range is (1200-1750 rpm). 1. Apply a small amount of Ford Light Duty Body Shop Polish to the pad. ^ Always keep the face of the buffing pad completely flat to the surface, reducing the risk of buffer swirl marks. Watch your pad, especially on angled surfaces, to be certain that it stays flat ^ When "buffing out" oxidation or other paint defects with a cleaning material, use a liberal amount of material, slower buffing motion and added downward pressure to increase cutting action 2. When polishing, keep the pad flat against the surface. Do not bear down. The weight of the buffer is suffi6ient. CAUTION: DO NOT MIX PRODUCTS. USE A SEPARATE, DEDICATED BUFFING PAD FOR EACH PRODUCT TO ACHIEVE DESIRED RESULTS. Med. Scratches, Small Dirt Particles, Grind & Sanding Marks 1. Apply Ford Medium Duty Body Shop Paint Cleaner to the panel with a clean compound pad on the wheel. 2. Spread the product evenly and continue buffing until the condition is removed. 3. Keep the wheel flat to the surface and use light to moderate pressure and long strokes. 4. Periodically check the finish and add product as required. 5. When buffing is complete, polish the panel as described previously. Untreated wool cutting pads are the most effective cutting pads to use with Ford Heavy Duty Body Shop Paint Cleaner for removing paint defects and heavy oxidation. Following the use of a wool cutting pad, it may be necessary to polish the finish with a foam pad to remove the deep swirl marks. NOTE: ALWAYS KEEP THE PAD MOVING AND LIMIT YOUR STROKES OVER THE BLEMISH TO PREVENT EXCESSIVE HEAT BUILDUP AND POSSIBLE BURN-THROUGH. STOP IMMEDIATELY IF THE SURFACE BECOMES TOO HOT TO LAY THE PALM OF YOUR HAND ON IT. KEEP SURFACE TEMPERATURE BELOW 38°C (100°F). NOTE: HEAT BUILDUP: WHEN BUFFING CREATES EXCESSIVE HEAT, HAZING MAY APPEAR ACROSS THE SURFACE BEING BUFFED AND THE PRODUCT MAY DRY LIKE A FILM AND REFUSE TO BUFF OUT. TO REMEDY, WIPE THE AREA DOWN WITH COOL WATER, DRY THE SURFACE AND RESUME BUFFING, AT A LOWER RPM IF POSSIBLE. NOTE: STATIC: STATIC ELECTRICITY MAY BE PRESENT ON A PAINTED FIBERGLASS/PLASTIC SURFACE BEING BUFFED. THE MATERIAL MAY DRY LIKE A FILM OR TURN "GUMMY" AND BEGIN TO BALL UP. TO REMEDY, ATTACH A GROUNDING CLAMP TO THE SURFACE BEING BUFFED TO ELIMINATE THE STATIC CHARGE. Run and Sag Removal This procedure consists of shaving the run(s) or sag(s) flush with a commercial single edge razor blade, shaving file or sanding. NOTE: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 98-3-3 > Feb > 98 > Paint - Surface Defect Removal Without Repainting > Page 11390 IF IT IS NECESSARY TO SHAVE RUNS AND SAGS WITH A RAZOR BLADE, FIRST DULL THE CORNERS WITH SANDPAPER TO AVOID SCRATCHING THE ADJACENT AREA FINISH. 1. Lightly scrape the defect until the defect is level with the surface. 2. Wet sand or compound the surface to remove any small scratches. 3. Polish to complete the repair. Wet Sanding For Defect Removal ^ Typical paint defects that are repaired with this system include: dirt in paint, solvent "pop," cratering, "orange peel," drips, scratches, water spots, and acid rain ^ Always use the least abrasive (highest grit) sanding products possible to do this job The following wet sanding procedure utilizes light grit sandpaper or sanding blocks for removal of surface damage. These materials cut quickly, leaving a uniform finish requiring a minimum of buffing to restore gloss. 1. Mist or apply water on the area to be sanded. Continue to flush water on the surface during sanding for maximum lubrication. 2. Use sanding blocks or paper. Keep abrasion to the immediate area of the defect. Keep blocks in water when not in use. 3. If the cutting is too slow, switch to a lower grade block or paper and resume sanding. When 90% of the defect is removed, switch to a 2000 grade sand paper or sanding block to finish smoothing and prepare the surface for buffing. 4. Sanding blocks can be shaped to work on any angle. When the block is wet, rub it against a dry sanding block for shaping. 5. When using sanding papers, wrap the paper tightly around a backing pad. This pad evenly distributes pressure over the entire surface of the sanding paper. This creates a uniform sanding pattern. 6. Plan your strokes to limit the abrasion to the smallest area possible. 7. Always finish sanding with 2000 Grit Sanding Paper. 2000 grit paper will reduce the need for heavy compound, however, the area should be finished by using a cleaner that will remove the sanding scratches left by these papers. NOTE: IF MULTIPLE GRIT PAPERS ARE USED, IT IS A GOOD IDEA TO CHANGE THE DIRECTION OF SANDING STROKE TO ALLOW YOU TO SEE THAT THE PREVIOUS GRIT SCRATCH IS REMOVED. 8. Buff out sanding marks by applying Ford Medium Duty Body Shop Paint Cleaner with a "Foam" Cutting Pad (W7000). Follow with Ford Light Duty Body Shop Polish for a swirl-free gloss. General Techniques and Hints ^ "Foam" buffing pads yield maximum gloss and depth of color on all types of paint finishes without creating buffer swirl marks ^ Always apply product directly to pad, not to oxidized paint surface. Dry paint absorbs material into pores upon contact ^ Avoid short rapid strokes. Move the buffer slowly across the surface using long straight motions and overlap by 50% the buffing pattern left by the previous pass. This insures uniform coverage and allows both material and buffer to perform at maximum efficiency ^ Avoid buffing directly on raised character lines. The reduced paint film on these surfaces increases the risk of paint burn-through. It is best to buff up to them from each side ^ If a paint blemish remains after buffing, reapply a small amount of material over the blemish~ Confine your buffing strokes to the immediate area of the blemish while applying additional downward pressure and keeping the pad flat Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 96201 > Sep > 96 > Paint - Codes and Colors/Cross Reference Paint: All Technical Service Bulletins Paint - Codes and Colors/Cross Reference Article No. 96-20-1 09/23/96 PAINT - 1997 COLOR CHART - AFTERMARKET SUPPLIER CROSS - REFERENCE LIST FORD: 1997 ASPIRE, CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1997 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VIII, MYSTIQUE, SABLE, TOWN CAR, TRACER LIGHT TRUCK: 1997 AEROSTAR, ECONOLINE, EXPEDITION, EXPLORER, F SUPER DUTY, F-150-350 SERIES, MOUNTAINEER, RANGER, VILLAGER, WINDSTAR MEDIUM/HEAVY TRUCK: 1997 AEROMAX, CARGO SERIES, F & B SERIES, L SERIES, LOUISVILLE ISSUE: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 96201 > Sep > 96 > Paint - Codes and Colors/Cross Reference > Page 11395 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 96201 > Sep > 96 > Paint - Codes and Colors/Cross Reference > Page 11396 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 96201 > Sep > 96 > Paint - Codes and Colors/Cross Reference > Page 11397 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 96201 > Sep > 96 > Paint - Codes and Colors/Cross Reference > Page 11398 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 96201 > Sep > 96 > Paint - Codes and Colors/Cross Reference > Page 11399 The 1997 Ford and Lincoln-Mercury color charts (Figures 1 through 5) provide all of the supplier paint code numbers for the Ford two-digit paint codes listed on the Vehicle Certification Label. ACTION: Paint should be available in either enamel or urethane from the manufacturers. To get the color match, use of either "Factory Pack" or "Intermix" is acceptable. OTHER APPLICABLE ARTICLES: 92-20-1, 93-24-4, 95-23-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 98-9-15 > May > 98 > ABS - Lamp ON/DTC B1342 Stored Paint: All Technical Service Bulletins Paint - Materials For After Warranty/Warranty Repairs Article No. 98-18-2 09/14/98 PAINT - EXTERIOR - WORLDWIDE RECOMMENDED PAINT MATERIALS FOR WARRANTY AND AFTER WARRANTY REPAIRS FORD: 1997 ASPIRE, PROBE, THUNDERBIRD 1997-98 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1997 COUGAR 1997-98 CONTINENTAL, GRAND MARQUIS, MARK VIII, MYSTIQUE, SABLE, TOWN CAR, TRACER LIGHT TRUCK: 1997 AEROSTAR 1997-98 ECONOLINE, EXPEDITION, EXPLORER, F SUPER DUTY, F-150-350 SERIES, F-47, MOUNTAINEER, RANGER, VILLAGER, WINDSTAR 1998 NAVIGATOR MEDIUM/HEAVY TRUCK: 1997-98 AEROMAX, CARGO SERIES, F & B SERIES, L SERIES, LOUISVILLE This TSB article is being republished in its entirety to add additional paint information. ISSUE Ford Motor Company's goal is to eliminate paint related repeat repairs and increase customer satisfaction. To meet this goal, Ford has tested refinish paint materials that are used for warranty. Tests conducted were designed around OEM Refinish Material Reliability and Durability Standards. ACTION Ford Customer Service Division (FCSD) has released a paint material specification (WSS-M2P100-D) to the major worldwide paint supply companies for testing refinish paint systems. These paint systems are used for refinishing service parts as well as repair steel and plastic OEM finishes. SYSTEMS TESTED Ford Motor Company has completed testing of refinish paint materials that are compliant to U.S. "National Rule," "Canadian Rule" and European VOC (Volatile Organic Compounds) regulations. NOTE TESTING OF CALIFORNIA VOC COMPLIANT SYSTEMS WILL BEGIN 9/98 DUE TO A RECENT MORATORIUM REQUIRING NEW EMISSION COMPLIANT PRODUCTS. SELECTION AND PREPARATION Each paint manufacturer was asked to submit worldwide "in-use" paint systems for testing. The paint materials used for testing were obtained by Ford from local paint jobbers and distributors and/or shipped in from Europe. Employees of each paint company prepared and sprayed the test panels. All testing was completed at the Ford Central Laboratory facility. SUBSTRATES AND TESTS The paint materials approved from these specifications were tested over the following substrates: cold rolled steel, E-coated steel, bare galvanized steel, sanded OEM finish, and TPO plastic. A select group of tests including salt spray, initial adhesion, chipping, fuel resistance, and thermal shock were used for screening. As the companies passed the screening tests, they were required to complete the balance of the tests listed in the specifications. Each panel was tested and reviewed per OEM testing methods. PAINT PRODUCT CHANGES If a paint company decides to introduce a new product into a tested system (i.e., new primer, same clearcoat), the entire system will require retesting. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 98-9-15 > May > 98 > ABS - Lamp ON/DTC B1342 Stored > Page 11405 Systems will only be tested once a year. Cost of testing will be the responsibility of the paint suppliers. APPROVED SUPPLIERS AND MATERIALS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 98-9-15 > May > 98 > ABS - Lamp ON/DTC B1342 Stored > Page 11406 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 98-9-15 > May > 98 > ABS - Lamp ON/DTC B1342 Stored > Page 11407 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 98-9-15 > May > 98 > ABS - Lamp ON/DTC B1342 Stored > Page 11408 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 98-9-15 > May > 98 > ABS - Lamp ON/DTC B1342 Stored > Page 11409 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 98-9-15 > May > 98 > ABS - Lamp ON/DTC B1342 Stored > Page 11410 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 98-9-15 > May > 98 > ABS - Lamp ON/DTC B1342 Stored > Page 11411 The Charts following this article (Figures 1-7) indicate paint suppliers and materials. Dealers should begin to use the recommended paint materials as soon as practical. Dealers without a body shop should provide a copy of this bulletin to the independent body shop performing their warranty repairs. The products listed in this bulletin may be made mandatory sometime in the future. As a result, dealers that have jobber/paint company contractual agreements should only contract with recommended suppliers (when existing contracts expire) CONCLUSIONS Testing of refinish materials will raise standards for these materials. These improved standards will result in improved customer satisfaction. OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 98-9-15 > May > 98 > ABS - Lamp ON/DTC B1342 Stored > Page 11412 SUPERSEDES: 98-9-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000, 190000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 11413 Paint: By Symptom Technical Service Bulletin # 99-12-10 Date: 990614 Paint - Rough Texture Article No. 99-12-10 06/14/99 ^ PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN NEUTRALIZATION ^ PAINT - ROUGH TEXTURE/FERROUS METAL CONTAMINATION - ACID RAIN DISCOLORATION OR ETCHING FORD: 1996-1997 ASPIRE, PROBE, THUNDERBIRD 1996-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1996-1997 COUGAR 1996-1998 MARK VIII 1996-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR LIGHT TRUCK: 1996 BRONCO 1996-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1996-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1996-1997 CARGO SERIES 1996-1998 AEROMAX, F SERIES, LOUISVILLE This TSB article is being republished in its entirety to add vehicles and model years, and to revise the procedure to use Ford brand service parts. ISSUE Ford Motor Company has released a private labeled material to be used for iron particle/acid rain service repairs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 11414 ACTION To remove these particles/contaminates, use ONLY the following products and procedure. No polishing, compounding, color sanding, or repainting should be done before this procedure is performed. This procedure uses products that are acidic, alkaline, and neutral and must be properly mixed and used in their specific order. Refer to the following Service Procedure for details. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 11415 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-21-3 WARRANTY STATUS: Eligible Under The Provisions Of 12 Month/12,000 Mile Basic Warranty Coverage OPERATION DESCRIPTION TIME 991210A Decontaminate And 0.6 Hr. Surface Correction (Aspire, F-450/550, And Cargo) 991210B Decontaminate And 0.7 Hr. Surface Correction (Escort ZX2, Ranger Regular Cab, Probe, Bronco, And Aerostar) 991210C Decontaminate And 0.8 Hr. Surface Correct (Escort/Tracer, Escort/Tracer Wagon, Contour/Mystique, Mustang Convertible/Convertible OT, Taurus/Sable Sedan Or Wagon, 1996-1998 Villager, And 1999 Cougar) 991210D Decontaminate And 0.8 Hr. Surface Correction (F-Series And 1996-97 Thunderbird/Cougar) 991210E Decontaminate And 0.8 Hr. Surface Correction (Ranger SuperCab/Splash, F-150/250 6Ft Bed - Regular Cab/Flare Side Regular Cab, F-250/350 SD 6Ft Bed - Regular Cab, F-450/550 Crew Cab, And Louisville/AeroMax) 991210F Decontaminate And 0.9 Hr. Surface Correction (Mustang Coupe/Coupe GT, Continental, Mark VIII, Ranger Splash SuperCab, Explorer 2-Door, And 1999 Villager) 991210G Decontaminate And 0.9 Hr. Surface Correction (F-150/250 6Ft Bed - SuperCab/8Ft Bed - Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 11416 Regular Cab/Flare Side - SuperCab, And F-250/350 SD 6Ff Bed - SuperCab/8Ft Bed - Regular Cab) 991210H Decontaminate And 1.0 Hr. Surface Correction (Crown Victoria/Grand Marquis, Town Car, Windstar, Explorer 4-Door, And Mountaineer) 9912101 Decontaminate And 1.0 Hr. Surface Correction (F-150/250 8Ft Bed - SuperCab, F-250/350 SD 6Ft Bed - Crew Cab/8Ft Bed SuperCab/8Ft Bed - Crew Cab, And Expedition/Navigator) 991210J Decontaminate And 1.2 Hrs. Surface Correction (Econoline Wagon/Wagon Super-V) 991210k Decontaminate And 1.3 Hrs. Surface Correction (Econoline Cargo) 991210L Decontaminate And 1.4 Hrs. Surface Correction (Econoline Cargo Super-V) DEALER CODING CONDITION BASIC PART NO. CODE ENTRE C8 OASIS CODES: 106000,190000 Service Procedure NOTE ANY CHANGES TO THIS PROCEDURE WILL CAUSE AN INCOMPLETE OR UNSATISFACTORY REPAIR. THE USE OF ANY OTHER PRODUCT OR PROCEDURE MAY CAUSE DAMAGE TO ALUMINUM OR PAINTED SURFACES. NOTE THE PRODUCTS USED TO REMOVE SURFACE CONTAMINATION FROM PAINT ARE DESIGNED FOR VEHICLES WHICH HAVE EXPERIENCED EXPOSURE FOR LESS THAN 120 DAYS. VEHICLES THAT EXCEED 120 DAYS OF EXPOSURE MAY REQUIRE THE PROCEDURE BE REPEATED TO RESOLVE THE CONCERN. ONCE THIS PROCEDURE IS COMPLETED, IT MAY BE NECESSARY TO PERFORM POLISHING OR REFINISHING PROCEDURES AFTER VEHICLE INSPECTION. Identification Ferrous metal particles (hot iron dust) are generated by manufacturing facilities, rail shipments, etc. These particles mechanically bond to a vehicle's painted surfaces. Moisture and temperature combine with particles to create a chemical reaction. This reaction creates an acid, causing the iron to corrode and enter the paint surface. Industrial fallout and acid rain generate corrosive compounds that fall on the vehicle's painted surfaces. When subjected to moisture and temperature, chemical compounds are created that etch the paint surface. To assist in identitying surface contamination, use a (Tandy-Radio Shack # 63-851) 30x lighted magnifier. Concern Description Ferrous Metal Light Colored Vehicles: Small orange stains the size of "mechanical pencil lead." The surface is rough to the touch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 11417 Dark Colored Vehicles: Small white or silver appearing dots with a rainbow ring around the dot. The surface is rough to the touch. Industrial Fallout Water spots with ferrous metal are present and the surface is rough to the touch. Acid Rain/Etching ^ Surface will exhibit irregular discolored spotting. ^ Dark colored vehicles may exhibit cloudy or graying spots where the acid has begun to etch the paint. ^ Extreme cases of etching will be visible and may be felt. Decontamination Procedure Use Ford Acid Neutralizer, Alkaline Neutralizer, and Detail Wash to decontaminate and neutralize the paint surface. Perform the procedure only on vehicle when the paint surface temperature is cool. Follow the step-by-step procedure listed below to perform this service operation. 1. Rinse off dust, dirt, and debris with cold water. Flush liberally. 2. Prepare Acid Neutralizer by mixing 8 parts of water to 1 part Acid Neutralizer in a bucket. 3. Use a clean wash mitt and apply mixture of Acid Neutralizer to the entire vehicle starting at the top of the vehicle working toward the side. Keep the vehicle wet with solution, lightly agitating for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. NOTE USE A SEPARATE MITT FOR EACH PRODUCT. DO NOT INTERMIX MITTS. 4. Rinse the vehicle thoroughly with cold water to remove Acid Neutralizer. 5. Dry only the horizontal surfaces of the vehicle at this time. Do not dry glass. 6. Alkaline Neutralizer is ready to use. Do not mix with water. Pour the contents into a dispenser squirt bottle. Squirt Alkaline Neutralizer directly onto a clean wash mitt. Do not spray Alkaline Neutralizer on the painted surface. Apply the product to the vehicle, keeping the areas wet and lightly agitated for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. 7. Rinse the vehicle thoroughly with cold water. 8. Prepare Detail Wash by mixing 29.5 mL (1 ounce) of Detail Wash to 3.7L (1 gallon) of water. 9. Shampoo the vehicle with Detail Wash using a clean wash mitt. Rinse the vehicle with cold water and dry the vehicle completely. NOTE DETAIL WASH IS A HEAVY DUTY NEUTRAL SHAMPOO CONCENTRATE (pH 7) AND MAY BE USED FOR HAND CAR WASHING OR IN AUTOMATIC CAR WASH SYSTEMS. Surface Correction Following Decontam./Neutralization 1. Visually inspect paint surface for evidence of removal of ferrous metal particles and water spots. NOTE ACID RAIN DISCOLORING OR ETCHING WILL REQUIRE ADDITIONAL PROCEDURES DEPENDENT ON DEPTH OF DAMAGE; POLISHING, BUFFING, COLOR SANDING, OR IN EXTREME CASES, REFINISHING. 2. Do Not Intermix Buffing Products. Use only one manufacturer's products. 3. Always follow the manufacturer's product usage sequence. Use the appropriate recommended pad at recommended buffing speeds as specified by the product manufacturer. NOTE WHEN ATTEMPTING TO AFFECT A REPAIR BY BUFFING, POLISHING, OR COLOR SANDING, DO NOT REMOVE AN EXCESS OF 0.3 MIL OF PAINT FILM OR REFINISHING WILL BE REQUIRED. USE OF AN ELECTRONIC MIL GAUGE (ROTUNDA 164-R4025) IS HIGHLY RECOMMENDED TO INSURE CONTROL OF PAINT FILM REMOVAL. 4. Use a dual action sander with a Velcro backing plate and a foam pad to fine polish and remove any swirls created by a rotary buffer or pad. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 11418 5. Use an alcohol and water mixture (1 to 1 ratio) to clean the buffed areas and to verify removal of scratches and swirls before application of the final polish. Technical Service Bulletin # 99-12-10 Date: 990614 Paint - Rough Texture Article No. 99-12-10 06/14/99 ^ PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN NEUTRALIZATION ^ PAINT - ROUGH TEXTURE/FERROUS METAL CONTAMINATION - ACID RAIN DISCOLORATION OR ETCHING FORD: 1996-1997 ASPIRE, PROBE, THUNDERBIRD 1996-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1996-1997 COUGAR 1996-1998 MARK VIII 1996-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR LIGHT TRUCK: 1996 BRONCO 1996-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1996-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1996-1997 CARGO SERIES 1996-1998 AEROMAX, F SERIES, LOUISVILLE This TSB article is being republished in its entirety to add vehicles and model years, and to revise the procedure to use Ford brand service parts. ISSUE Ford Motor Company has released a private labeled material to be used for iron particle/acid rain service repairs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 11419 ACTION To remove these particles/contaminates, use ONLY the following products and procedure. No polishing, compounding, color sanding, or repainting should be done before this procedure is performed. This procedure uses products that are acidic, alkaline, and neutral and must be properly mixed and used in their specific order. Refer to the following Service Procedure for details. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 11420 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-21-3 WARRANTY STATUS: Eligible Under The Provisions Of 12 Month/12,000 Mile Basic Warranty Coverage OPERATION DESCRIPTION TIME 991210A Decontaminate And 0.6 Hr. Surface Correction (Aspire, F-450/550, And Cargo) 991210B Decontaminate And 0.7 Hr. Surface Correction (Escort ZX2, Ranger Regular Cab, Probe, Bronco, And Aerostar) 991210C Decontaminate And 0.8 Hr. Surface Correct (Escort/Tracer, Escort/Tracer Wagon, Contour/Mystique, Mustang Convertible/Convertible OT, Taurus/Sable Sedan Or Wagon, 1996-1998 Villager, And 1999 Cougar) 991210D Decontaminate And 0.8 Hr. Surface Correction (F-Series And 1996-97 Thunderbird/Cougar) 991210E Decontaminate And 0.8 Hr. Surface Correction (Ranger SuperCab/Splash, F-150/250 6Ft Bed - Regular Cab/Flare Side Regular Cab, F-250/350 SD 6Ft Bed - Regular Cab, F-450/550 Crew Cab, And Louisville/AeroMax) 991210F Decontaminate And 0.9 Hr. Surface Correction (Mustang Coupe/Coupe GT, Continental, Mark VIII, Ranger Splash SuperCab, Explorer 2-Door, And 1999 Villager) 991210G Decontaminate And 0.9 Hr. Surface Correction (F-150/250 6Ft Bed - SuperCab/8Ft Bed - Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 11421 Regular Cab/Flare Side - SuperCab, And F-250/350 SD 6Ff Bed - SuperCab/8Ft Bed - Regular Cab) 991210H Decontaminate And 1.0 Hr. Surface Correction (Crown Victoria/Grand Marquis, Town Car, Windstar, Explorer 4-Door, And Mountaineer) 9912101 Decontaminate And 1.0 Hr. Surface Correction (F-150/250 8Ft Bed - SuperCab, F-250/350 SD 6Ft Bed - Crew Cab/8Ft Bed SuperCab/8Ft Bed - Crew Cab, And Expedition/Navigator) 991210J Decontaminate And 1.2 Hrs. Surface Correction (Econoline Wagon/Wagon Super-V) 991210k Decontaminate And 1.3 Hrs. Surface Correction (Econoline Cargo) 991210L Decontaminate And 1.4 Hrs. Surface Correction (Econoline Cargo Super-V) DEALER CODING CONDITION BASIC PART NO. CODE ENTRE C8 OASIS CODES: 106000,190000 Service Procedure NOTE ANY CHANGES TO THIS PROCEDURE WILL CAUSE AN INCOMPLETE OR UNSATISFACTORY REPAIR. THE USE OF ANY OTHER PRODUCT OR PROCEDURE MAY CAUSE DAMAGE TO ALUMINUM OR PAINTED SURFACES. NOTE THE PRODUCTS USED TO REMOVE SURFACE CONTAMINATION FROM PAINT ARE DESIGNED FOR VEHICLES WHICH HAVE EXPERIENCED EXPOSURE FOR LESS THAN 120 DAYS. VEHICLES THAT EXCEED 120 DAYS OF EXPOSURE MAY REQUIRE THE PROCEDURE BE REPEATED TO RESOLVE THE CONCERN. ONCE THIS PROCEDURE IS COMPLETED, IT MAY BE NECESSARY TO PERFORM POLISHING OR REFINISHING PROCEDURES AFTER VEHICLE INSPECTION. Identification Ferrous metal particles (hot iron dust) are generated by manufacturing facilities, rail shipments, etc. These particles mechanically bond to a vehicle's painted surfaces. Moisture and temperature combine with particles to create a chemical reaction. This reaction creates an acid, causing the iron to corrode and enter the paint surface. Industrial fallout and acid rain generate corrosive compounds that fall on the vehicle's painted surfaces. When subjected to moisture and temperature, chemical compounds are created that etch the paint surface. To assist in identitying surface contamination, use a (Tandy-Radio Shack # 63-851) 30x lighted magnifier. Concern Description Ferrous Metal Light Colored Vehicles: Small orange stains the size of "mechanical pencil lead." The surface is rough to the touch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 11422 Dark Colored Vehicles: Small white or silver appearing dots with a rainbow ring around the dot. The surface is rough to the touch. Industrial Fallout Water spots with ferrous metal are present and the surface is rough to the touch. Acid Rain/Etching ^ Surface will exhibit irregular discolored spotting. ^ Dark colored vehicles may exhibit cloudy or graying spots where the acid has begun to etch the paint. ^ Extreme cases of etching will be visible and may be felt. Decontamination Procedure Use Ford Acid Neutralizer, Alkaline Neutralizer, and Detail Wash to decontaminate and neutralize the paint surface. Perform the procedure only on vehicle when the paint surface temperature is cool. Follow the step-by-step procedure listed below to perform this service operation. 1. Rinse off dust, dirt, and debris with cold water. Flush liberally. 2. Prepare Acid Neutralizer by mixing 8 parts of water to 1 part Acid Neutralizer in a bucket. 3. Use a clean wash mitt and apply mixture of Acid Neutralizer to the entire vehicle starting at the top of the vehicle working toward the side. Keep the vehicle wet with solution, lightly agitating for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. NOTE USE A SEPARATE MITT FOR EACH PRODUCT. DO NOT INTERMIX MITTS. 4. Rinse the vehicle thoroughly with cold water to remove Acid Neutralizer. 5. Dry only the horizontal surfaces of the vehicle at this time. Do not dry glass. 6. Alkaline Neutralizer is ready to use. Do not mix with water. Pour the contents into a dispenser squirt bottle. Squirt Alkaline Neutralizer directly onto a clean wash mitt. Do not spray Alkaline Neutralizer on the painted surface. Apply the product to the vehicle, keeping the areas wet and lightly agitated for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. 7. Rinse the vehicle thoroughly with cold water. 8. Prepare Detail Wash by mixing 29.5 mL (1 ounce) of Detail Wash to 3.7L (1 gallon) of water. 9. Shampoo the vehicle with Detail Wash using a clean wash mitt. Rinse the vehicle with cold water and dry the vehicle completely. NOTE DETAIL WASH IS A HEAVY DUTY NEUTRAL SHAMPOO CONCENTRATE (pH 7) AND MAY BE USED FOR HAND CAR WASHING OR IN AUTOMATIC CAR WASH SYSTEMS. Surface Correction Following Decontam./Neutralization 1. Visually inspect paint surface for evidence of removal of ferrous metal particles and water spots. NOTE ACID RAIN DISCOLORING OR ETCHING WILL REQUIRE ADDITIONAL PROCEDURES DEPENDENT ON DEPTH OF DAMAGE; POLISHING, BUFFING, COLOR SANDING, OR IN EXTREME CASES, REFINISHING. 2. Do Not Intermix Buffing Products. Use only one manufacturer's products. 3. Always follow the manufacturer's product usage sequence. Use the appropriate recommended pad at recommended buffing speeds as specified by the product manufacturer. NOTE WHEN ATTEMPTING TO AFFECT A REPAIR BY BUFFING, POLISHING, OR COLOR SANDING, DO NOT REMOVE AN EXCESS OF 0.3 MIL OF PAINT FILM OR REFINISHING WILL BE REQUIRED. USE OF AN ELECTRONIC MIL GAUGE (ROTUNDA 164-R4025) IS HIGHLY RECOMMENDED TO INSURE CONTROL OF PAINT FILM REMOVAL. 4. Use a dual action sander with a Velcro backing plate and a foam pad to fine polish and remove any swirls created by a rotary buffer or pad. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 11423 5. Use an alcohol and water mixture (1 to 1 ratio) to clean the buffed areas and to verify removal of scratches and swirls before application of the final polish. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Page 11424 Paint: Application and ID The exterior paint color codes are: ^ BA - LT Prairie Tan C/C. ^ E9 - Laser Red Tint C/C. ^ F7 - Vermont Green C/C. ^ JL - Dark Toreador C/C. ^ KM - Royal Blue C/C. ^ PS - Pacific Green C/C. ^ TS - Silver Frost C/C. ^ UA - Ebony C/C. ^ XC - Portofino Blue C/C. ^ YZ - Oxford White C/C. ^ Y1 - Prime. NOTE: All colors except prime include a Clear Coat (C/C). NOTE: Two codes indicates two-tone paint. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Heated Mirror Relay > Component Information > Locations Heated Mirror Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Heated Mirror Relay > Component Information > Locations > Page 11429 Junction Box Fuse/Relay Panel (Part 1 Of 2) The Heated Grid Relay is located in junction box fuse/relay panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Specifications Keyless Entry Module: Specifications RAP Module Nuts ................................................................................................................................ ...................................................... 7 Nm (62.4 in lb) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Specifications > Page 11433 Keyless Entry Module: Locations Body Views Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Specifications > Page 11434 The Remote Anti-Theft Personality Module is located behind left side of instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Specifications > Page 11435 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect the C257 and C256 Remote Anti-theft Personality (RAP) module electrical connectors. 2. Disconnect the antenna connector. 3. Remove the RAP module nuts and the RAP module. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > All Lock Relay Power Door Lock Relay: Locations All Lock Relay Body View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 11440 Lock Relays The All Lock Relay is located in lock relays. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 11441 Power Door Lock Relay: Locations All Unlock Relay Body View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 11442 Lock Relays The All Lock Relay is located in lock relays. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 11443 Power Door Lock Relay: Locations Driver's Door Unlock Relay Body View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 11444 Lock Relays The Driver's Unlock Relay is located in lock relays. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > All Lock Relay > Page 11445 Power Door Lock Relay: Locations Lock Relays Body View The Lock Relays are located behind right side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Relay > Component Information > Locations Sunroof / Moonroof Relay: Locations RPO Relay Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Relay > Component Information > Locations > Page 11449 Instrument Panel View The Vent Window/Moonroof Relay is located in the regular production option (RPO) relay block which is located in the Dash, above the passenger air bag. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Relay > Component Information > Locations > Page 11450 Sunroof / Moonroof Relay: Testing and Inspection Testing of an ISO relay can be accomplished through the use of three No. 10 (or larger gauge) jumper wires and a 73 Digital Multimeter. Remove (unplug) the relay to be tested from the engine compartment fuse junction panel, I/P fuse junction panel or individual connector. Mini ISO Relay Use the 73 Digital Multimeter to check for the continuity between terminal 85 and all other terminals. If resistance is 5 ohms or less between terminal 85 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay terminals 86 and 30 directly to the positive battery terminal. With the 73 Digital Multimeter set in the volts position, check for voltage at terminal 87A. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 85 and ground the jumper wire to a known good ground. Check for voltage at terminal 87. If battery voltage is not indicated, replace the relay. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Specifications Sunroof / Moonroof Motor: Specifications Sliding Roof Panel Motor Bolts ............................................................................................................................................................ 4-6 Nm (36-53 in lb) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Specifications > Page 11456 Moonroof Motor Assembly Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Specifications > Page 11457 Sunroof / Moonroof Motor: Service and Repair REMOVAL 1. Remove the access cover. NOTE: The sliding roof glass should be in the closed position. 2. Remove the three bolts. 3. Disconnect the electrical connector and remove the sliding roof panel motor. INSTALLATION 1. Connect the electrical connector. NOTE: Sliding roof glass should be in the closed position. 2. Cycle the sliding roof panel motor sliding roof panel motor until it stops in the closed position. 3. Remove the glass panel. 4. Insert two 1/8 inch pins through both portions of the lifter assemblies. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Specifications > Page 11458 5. Install the sliding roof panel motor. ^ Install the three bolts. NOTE: It may be necessary to rotate the sliding roof panel motor slightly to engage the drive splines. 6. Remove the pins. 7. Install the glass panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Relay > Component Information > Locations Sunroof / Moonroof Relay: Locations RPO Relay Box Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Relay > Component Information > Locations > Page 11462 Instrument Panel View The Vent Window/Moonroof Relay is located in the regular production option (RPO) relay block which is located in the Dash, above the passenger air bag. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Relay > Component Information > Locations > Page 11463 Sunroof / Moonroof Relay: Testing and Inspection Testing of an ISO relay can be accomplished through the use of three No. 10 (or larger gauge) jumper wires and a 73 Digital Multimeter. Remove (unplug) the relay to be tested from the engine compartment fuse junction panel, I/P fuse junction panel or individual connector. Mini ISO Relay Use the 73 Digital Multimeter to check for the continuity between terminal 85 and all other terminals. If resistance is 5 ohms or less between terminal 85 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay terminals 86 and 30 directly to the positive battery terminal. With the 73 Digital Multimeter set in the volts position, check for voltage at terminal 87A. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 85 and ground the jumper wire to a known good ground. Check for voltage at terminal 87. If battery voltage is not indicated, replace the relay. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams Moonroof Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Customer Interest for Power Seat Switch: > 98-20-19 > Oct > 98 > Power Seat Switch - Button Comes Off Power Seat Switch: Customer Interest Power Seat Switch - Button Comes Off Article No. 98-20-19 10/12/98 POWER SEAT SWITCH - BUTTON COMES OFF LIGHT TRUCK: 1995-99 EXPLORER 1997-99 ECONOLINE, EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE The power seat control button (knob) may detach from the switch actuator. This may be due to insufficient adhesion between the button and the switch actuator. ACTION Attach a new button and use an adhesive to reduce the possibility of the button detaching from the actuator. The button was not previously adhered. This revised process has been tested for shear and pull strengths. Refer to the following text for details. Refer to the Instruction Sheet included with Knob Kit (F85Z-14711-AA). Ford Instant Adhesive (E8AZ-19554-A) or equivalent meeting Ford specification WSK-M2G402-A4 is not included with the kit, but is required to complete this repair procedure. Order Ford Instant Adhesive separately. PART NUMBER PART NAME F85Z-14711-AA Knob Kit E8AZ-l9554-A Instant Adhesive OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982019A Install Power Seat Control 0.2 Hr. Button DEALER CODING CONDITION BASIC PART NO. CODE 14711 68 OASIS CODES: 101000, 107000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Seat Switch: > 98-20-19 > Oct > 98 > Power Seat Switch - Button Comes Off Power Seat Switch: All Technical Service Bulletins Power Seat Switch - Button Comes Off Article No. 98-20-19 10/12/98 POWER SEAT SWITCH - BUTTON COMES OFF LIGHT TRUCK: 1995-99 EXPLORER 1997-99 ECONOLINE, EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE The power seat control button (knob) may detach from the switch actuator. This may be due to insufficient adhesion between the button and the switch actuator. ACTION Attach a new button and use an adhesive to reduce the possibility of the button detaching from the actuator. The button was not previously adhered. This revised process has been tested for shear and pull strengths. Refer to the following text for details. Refer to the Instruction Sheet included with Knob Kit (F85Z-14711-AA). Ford Instant Adhesive (E8AZ-19554-A) or equivalent meeting Ford specification WSK-M2G402-A4 is not included with the kit, but is required to complete this repair procedure. Order Ford Instant Adhesive separately. PART NUMBER PART NAME F85Z-14711-AA Knob Kit E8AZ-l9554-A Instant Adhesive OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982019A Install Power Seat Control 0.2 Hr. Button DEALER CODING CONDITION BASIC PART NO. CODE 14711 68 OASIS CODES: 101000, 107000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 11481 Power Seat Switch: Specifications Seat Regulator Control Switch Screws ................................................................................................................................................... 1-3 Nm (9-26 in lb) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 11482 Power Seat Control Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 11483 Power Seat Switch: Testing and Inspection Left Front Seat Control Switch Left Front Seat Control Switch - Component Testing Procedure (Part 1 Of 2) Left Front Seat Control Switch - Component Testing Procedure (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 11484 Left Front Seat Control Switch - Terminal Locations Left Front Seat Control Switch - Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 11485 Power Seat Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front seat back adjust handle. 1. Remove the screw. 2. Remove the front seat back adjust handle. 3. Pull to remove the front seat lumbar support handle. 4. Remove the front seat track shield screws. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 11486 5. Remove the pushpin on the back of the front seat track shield. 6. Remove the screws on the bottom of the front seat track shield. 7. Disconnect the seat regulator control switch from the front of the front seat track shield. 1. Remove the screws. 2. Disconnect the seat regulator control switch. 8. Disconnect the seat regulator control switch electrical connector and remove the seat regulator control switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 11487 INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Customer Interest: > 98-13-13 > Jul > 98 > Front Leather Seats - Wear Prematurely Seat Cover: Customer Interest Front Leather Seats - Wear Prematurely Article No. 98-13-13 07/06/98 SEATS - FRONT LEATHER SEATS WEAR PREMATURELY - VEHICLES BUILT THROUGH 12/16/97 LIGHT TRUCK: 1997-98 EXPEDITION ISSUE The front leather seats may prematurely wear or wrinkle on some vehicles. This may be caused by the seat cover sticking to the foam cushion. ACTION Replace the leather seat cover with a revised seat cover which includes angel hair to be placed between the cover and foam cushion. The angel hair allows the leather cover to slide with the occupant on the foam cushion, reducing the possibility of premature wear. Refer to the text for details. For concerns of front leather seats wearing or wrinkling prematurely, use the appropriate service Seat Cover Kit (listed in the Parts Block), and obtain locally seven (7) hog rings per seat. Follow instructions (SK F85B-16A091-AA) included in the kit. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 981313A Install Leather Front Seat 1.0 Hr. Kit (One) 981313B Install Leather Front Seat 1.9 Hrs. Kit (Both) DEALER CODING CONDITION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Customer Interest: > 98-13-13 > Jul > 98 > Front Leather Seats - Wear Prematurely > Page 11496 BASIC PART NO. CODE 7860050 - 7860051 30 OASIS CODES: 101000, 107000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-17-1 > Sep > 98 > Seat Leather - Cleaning Procedure Tips Seat Cover: All Technical Service Bulletins Seat Leather - Cleaning Procedure Tips Article No. 98-17-1 09/01/98 SEAT - LEATHER CLEANING PROCEDURE - SERVICE TIP FORD: 1984-94 TEMPO 1984-97 THUNDERBIRD 1984-98 CROWN VICTORIA, ESCORT, MUSTANG 1986-98 TAURUS 1989-97 PROBE 1994-97 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1984-94 TOPAZ 1984-97 COUGAR 1984-98 GRAND MARQUIS, TRACER 1984-99 TOWN CAR 1986-98 SABLE 1993-98 MARK VIII 1995-98 MYSTIQUE 1995-99 CONTINENTAL 1999 COUGAR LIGHT TRUCK: 1983-98 RANGER 1984-96 BRONCO 1984-97 F-250 HD 1984-98 ECONOLINE, F-150, F-250 LD 1986-97 AEROSTAR 1991-98 EXPLORER 1993-98 VILLAGER 1996-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to include the latest level parts and to include a revised Service Procedure. ISSUE The following TSB contains information regarding the cleaning of interior leather seats and trim. Improper cleaning procedures may damage the leather. If seats are not cleaned on a regular basis (every 4-6 weeks), normal wear and tear can cause excessive soiling. ACTION Ford Motor Company has developed a new kit (Deluxe Leather Care Kit - F8AZ-19G253-AA) to clean soiled seats without damaging the top coat of the leather. The kit contains a leather and vinyl cleaner along with a specially formulated sponge. Refer to the text for cleaning leather seats and trim. The Deluxe Leather Care Kit has been tested and approved for use on all Ford and Lincoln/Mercury leather and vinyl seating surfaces, and if used as directed, should be used for service repairs. Many household cleaners and sponges are too harsh to be used on leather and may actually cause permanent damage to the surface. Use this material on leather and vinyl seats that: ^ show excessive soiling ^ have been stained with coffee, lipstick, etc. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-17-1 > Sep > 98 > Seat Leather - Cleaning Procedure Tips > Page 11502 Refer to the instructions included in the kit for specific application procedures. After cleaning surface with cleaner and sponge, wipe area with water and a cotton cloth. NOTE AVOID EXCESSIVE APPLICATION OF CLEANER ALONG STITCHING. PART NUMBER PART NAME F8AZ-19G253-AA Deluxe Leather Care Kit OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-14-2 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 101000, 107000, 190000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-13-13 > Jul > 98 > Front Leather Seats - Wear Prematurely Seat Cover: All Technical Service Bulletins Front Leather Seats - Wear Prematurely Article No. 98-13-13 07/06/98 SEATS - FRONT LEATHER SEATS WEAR PREMATURELY - VEHICLES BUILT THROUGH 12/16/97 LIGHT TRUCK: 1997-98 EXPEDITION ISSUE The front leather seats may prematurely wear or wrinkle on some vehicles. This may be caused by the seat cover sticking to the foam cushion. ACTION Replace the leather seat cover with a revised seat cover which includes angel hair to be placed between the cover and foam cushion. The angel hair allows the leather cover to slide with the occupant on the foam cushion, reducing the possibility of premature wear. Refer to the text for details. For concerns of front leather seats wearing or wrinkling prematurely, use the appropriate service Seat Cover Kit (listed in the Parts Block), and obtain locally seven (7) hog rings per seat. Follow instructions (SK F85B-16A091-AA) included in the kit. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 981313A Install Leather Front Seat 1.0 Hr. Kit (One) 981313B Install Leather Front Seat 1.9 Hrs. Kit (Both) DEALER CODING CONDITION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-13-13 > Jul > 98 > Front Leather Seats - Wear Prematurely > Page 11507 BASIC PART NO. CODE 7860050 - 7860051 30 OASIS CODES: 101000, 107000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cover: > 97-26-25 > Dec > 97 > Rear Sway Bar Link - Clunking/Rattling Noise Stabilizer Link: All Technical Service Bulletins Rear Sway Bar Link - Clunking/Rattling Noise Article No. 97-26-25 12/22/97 NOISE - "CLUNKING/RATTLING" NOISE COMING FROM REAR OF VEHICLE - VEHICLES BUILT THROUGH 4/11/97 LIGHT TRUCK: 1997 EXPEDITION ISSUE: A "clunking/rattling" noise may be heard from the rear of the vehicle when going over bumps. This may be caused by a bushing falling out of the rear sway bar link. ACTION: Replace the sway bar ink and install a washer onto the sway bar link. The washer should reduce the possibility of the bushing coming off of the sway bar link. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Replace the rear Sway Bar Link (F75Z-5K484-AA) and install a Washer (N800916-S100) on the end of the bolt that holds the link to the frame. Refer to the 1998 Expedition Workshop Manual for correct replacement procedures. 2. Torque the bolt to 103 N.m (76 lb-ft). 3. Repeat this for the opposite side of the vehicle. PART NUMBER PART NAME F75Z-5K484-AA Sway Bar Link N800916-S100 Washer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 972625AT Replace Link And Washer 0.5 Hr. - Both Sides 972625A Replace Link And Washer 0.4 Hr. - One Side DEALER CODING CONDITION BASIC PART NO. CODE 5K484 12 OASIS CODES: 303000, 304000, 305000, 702200, 702300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Specifications Seat Cushion: Specifications Second Row Seat Cushion Frame to Seat Back Frame Bolts ............................................................................................................ 17-29 Nm (12-21 ft lb) Second Row Seat Cushion Support Bar Bolts ................................................................................................................................... 17-29 Nm (12-21 ft lb) Third Row Seat Back Frame to Seat Cushion Frame Bolts ............................................................................................................... 21-29 Nm (16-21 ft lb) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Specifications Seat Track: Specifications Front Seat Manual Seat Track Release Bar Bolts .............................................................................................................................. 21-29 Nm (16-21 ft lb) Front Seat Track Bolts .................................................................................................................... ................................................... 21-29 Nm (16-21 ft lb) Front Seat Track Shield Screws .............................................................................................................................................................. 1-3 Nm (9-26 in lb) Front Seat Riser Support to Seat Track Bolts .................................................................................................................................... 44-55 Nm (33-40 ft lb) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Left Door Left Power Door Lock Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Left Door > Page 11529 Right Power Door Lock Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams Power Mirror Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Customer Interest for Power Seat Switch: > 98-20-19 > Oct > 98 > Power Seat Switch - Button Comes Off Power Seat Switch: Customer Interest Power Seat Switch - Button Comes Off Article No. 98-20-19 10/12/98 POWER SEAT SWITCH - BUTTON COMES OFF LIGHT TRUCK: 1995-99 EXPLORER 1997-99 ECONOLINE, EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE The power seat control button (knob) may detach from the switch actuator. This may be due to insufficient adhesion between the button and the switch actuator. ACTION Attach a new button and use an adhesive to reduce the possibility of the button detaching from the actuator. The button was not previously adhered. This revised process has been tested for shear and pull strengths. Refer to the following text for details. Refer to the Instruction Sheet included with Knob Kit (F85Z-14711-AA). Ford Instant Adhesive (E8AZ-19554-A) or equivalent meeting Ford specification WSK-M2G402-A4 is not included with the kit, but is required to complete this repair procedure. Order Ford Instant Adhesive separately. PART NUMBER PART NAME F85Z-14711-AA Knob Kit E8AZ-l9554-A Instant Adhesive OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982019A Install Power Seat Control 0.2 Hr. Button DEALER CODING CONDITION BASIC PART NO. CODE 14711 68 OASIS CODES: 101000, 107000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Seat Switch: > 98-20-19 > Oct > 98 > Power Seat Switch - Button Comes Off Power Seat Switch: All Technical Service Bulletins Power Seat Switch - Button Comes Off Article No. 98-20-19 10/12/98 POWER SEAT SWITCH - BUTTON COMES OFF LIGHT TRUCK: 1995-99 EXPLORER 1997-99 ECONOLINE, EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE The power seat control button (knob) may detach from the switch actuator. This may be due to insufficient adhesion between the button and the switch actuator. ACTION Attach a new button and use an adhesive to reduce the possibility of the button detaching from the actuator. The button was not previously adhered. This revised process has been tested for shear and pull strengths. Refer to the following text for details. Refer to the Instruction Sheet included with Knob Kit (F85Z-14711-AA). Ford Instant Adhesive (E8AZ-19554-A) or equivalent meeting Ford specification WSK-M2G402-A4 is not included with the kit, but is required to complete this repair procedure. Order Ford Instant Adhesive separately. PART NUMBER PART NAME F85Z-14711-AA Knob Kit E8AZ-l9554-A Instant Adhesive OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 982019A Install Power Seat Control 0.2 Hr. Button DEALER CODING CONDITION BASIC PART NO. CODE 14711 68 OASIS CODES: 101000, 107000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 11546 Power Seat Switch: Specifications Seat Regulator Control Switch Screws ................................................................................................................................................... 1-3 Nm (9-26 in lb) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 11547 Power Seat Control Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 11548 Power Seat Switch: Testing and Inspection Left Front Seat Control Switch Left Front Seat Control Switch - Component Testing Procedure (Part 1 Of 2) Left Front Seat Control Switch - Component Testing Procedure (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 11549 Left Front Seat Control Switch - Terminal Locations Left Front Seat Control Switch - Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 11550 Power Seat Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front seat back adjust handle. 1. Remove the screw. 2. Remove the front seat back adjust handle. 3. Pull to remove the front seat lumbar support handle. 4. Remove the front seat track shield screws. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 11551 5. Remove the pushpin on the back of the front seat track shield. 6. Remove the screws on the bottom of the front seat track shield. 7. Disconnect the seat regulator control switch from the front of the front seat track shield. 1. Remove the screws. 2. Disconnect the seat regulator control switch. 8. Disconnect the seat regulator control switch electrical connector and remove the seat regulator control switch. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 11552 INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams Moonroof Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Tailgate > Component Information > Technical Service Bulletins > Customer Interest: > 04-18-11 > Sep > 04 > Body - Corrosion At Bottom of Door or Tailgate Tailgate: Customer Interest Body - Corrosion At Bottom of Door or Tailgate TSB 04-18-11 09/20/04 BODY - CORROSION AT BOTTOM OF DOOR OR TAILGATE HEM FLANGE - REPAIR PROCEDURE FORD: 1997-2001 Taurus 2000-2001 Focus 1997-2001 Expedition, F-250 LD, Windstar, F-Series LINCOLN: 1998-2001 Navigator MERCURY: 1997-2001 Sable This article supersedes TSB 01-09-8 to update the vehicle line and model year coverage and service procedure. ISSUE Some vehicles may exhibit corrosion at the hem flange at bottom of any door/tailgate where the outer panel is folded over the inner panel. ACTION Repair corrosion at the hem flange using special hem flange tools. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE READ THIS REPAIR PROCEDURE COMPLETELY BEFORE PERFORMING ANY SERVICE ACTIONS. NOTE THE USE OF FORD OR MOTORCRAFT BRAND PRODUCTS ARE MANDATORY ON ALL REPAIR CLAIMS PAID BY FORD UNLESS OTHERWISE SPECIFIED IN EMISSIONS, SAFETY RECALLS, OWNER NOTIFICATION PROGRAMS, TSB'S OR OTHER COMPANY PUBLICATIONS. THE COST OF NON-FORD/MOTORCRAFT PRODUCTS USED FOR A WARRANTY, ESP/ESC OR AWA REPAIR WITHOUT JUSTIFYING THEIR USE (SUCH AS EMERGENCY REPAIR) IS NOT REIMBURSABLE. EXAMPLES OF FORD PRODUCTS ARE ADHESIVES, SEALERS, SOLVENTS, CLEANERS, WASHES, AND OTHER SPECIAL PRODUCTS LISTED IN THE FORD CAR CARE PRODUCTS MANUAL. NOTE TECHNICIANS SHOULD WEAR THE APPROPRIATE EYE, HAND AND HEARING PROTECTION WHILE PERFORMING THESE REPAIR PROCEDURES. ADHESIVES AND SEALERS USED IN THESE PROCEDURES SHOULD BE USED IN A WELL-VENTILATED AREA. 1. Inspect the inside of the door/tailgate at the lower edge only for corrosion/bubbling. 2. Follow the Workshop Manual procedure for the removal of the interior door panel or tailgate and tailgate moldings. 3. Use shop air to blow out the drain holes in the bottom of the door/tailgate and apply 25 mm (1") tape to the outer skin at the bottom to prevent scuffing. 4. Use a hammer and screwdriver to slightly lift the corner of the hem flange. 5. Insert TOOL 501-078/1(RT) or TOOL 501-078/2(LT) in an air impact gun (620 kPa (90 psi) air pressure is required for consistent tool operation). Using the tool lift the hem flange continuing across the bottom of the door/tailgate and stop just before the end. 6. Use an angle grinder or wire brush to remove all corrosion on the bottom of the hem flange and inner door/tailgate panel. Follow by blowing off with compressed air. 7. Using appropriate hand protection, brush on Corrosion Converter (Sem # 69508) on the corroded area. Use light coat and let flash dry 2-5 minutes. Follow by using a damp cloth to wipe off corrosion residue. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Tailgate > Component Information > Technical Service Bulletins > Customer Interest: > 04-18-11 > Sep > 04 > Body - Corrosion At Bottom of Door or Tailgate > Page 11564 8. Sand with a DA sander using 360 grit sand paper the lower areas of the door/tailgate where paint was disturbed, keeping the repair area small. Feather edge for a paint blend as necessary. Blow off the panel with clean compressed air. Clean the panels with wax and remover. 9. Mix and brush on Ford approved epoxy or self-etching primer to all bare hem flange areas on the bottom of the door/tailgate. Bake at 140°F (60° C) panel temperature per manufacturers label instructions. 10. Install the Motorcraft TA-1 adhesive cartridge into the application gun 501-040. Squeeze out some material to purge the cartridge. Install the tip on the cartridge and squeeze out some material to make sure of even mixing of the adhesive components. 11. Apply the adhesive between the hem flange and bottom of the inner door/tailgate panel. Work time is 45 minutes at 70°F (21°C). Adhesive cure time is 8 hours. 12. Use TOOL 501-080 to re-hem (close down) the hem flange. Start in a corner, and insert the center of the tool over the area to close down and hit with a hammer. 13. Install the Motorcraft TA-2 urethane cartridge into the application gun 501-040. Squeeze out some material to purge the cartridge. Install the tip on the cartridge and squeeze out some material to make sure of even mixing of the adhesive components. 14. Apply Motorcraft TA-2 urethane seam sealer around the door/tailgate hem flange to give a finished appearance. 15. Remove any residual sealer with adhesive remover. Sealer is paintable in 10 minutes and within 24 hours. 16. Mask the door/tailgate for color application. 17. Mix and apply Ford approved basecoat color to the inside of the door/tailgate area and allow material to flash off. 18. Mix and apply Ford approved clearcoat to inside of the door/tailgate and bake at 140°F (60°C) panel temperature per following manufacturers recommended baking time. 19. Spray Dominion Sure Seal Amber anti corrosion coating (24011) to the inside of the door/tailgate at the hem location. Do not plug drain holes. 20. Demask the vehicle and, reinstall the inner door panel or tailgate moldings. SPECIAL TOOLS ^ 501-078/1 RH Hem Opening Tool (Tools are direct ship from O.T.C.) ^ 501-078/2 LH Hem Opening Tool ^ 501-080 Hem Closing Tool ^ 501-040 Adhesive Gun (Adhesive Gun not included in kits. This is a commonly used commercially available gun. Must be ordered separately from Rotunda.) PARTS BLOCK WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Tailgate > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-18-11 > Sep > 04 > Body - Corrosion At Bottom of Door or Tailgate Tailgate: All Technical Service Bulletins Body - Corrosion At Bottom of Door or Tailgate TSB 04-18-11 09/20/04 BODY - CORROSION AT BOTTOM OF DOOR OR TAILGATE HEM FLANGE - REPAIR PROCEDURE FORD: 1997-2001 Taurus 2000-2001 Focus 1997-2001 Expedition, F-250 LD, Windstar, F-Series LINCOLN: 1998-2001 Navigator MERCURY: 1997-2001 Sable This article supersedes TSB 01-09-8 to update the vehicle line and model year coverage and service procedure. ISSUE Some vehicles may exhibit corrosion at the hem flange at bottom of any door/tailgate where the outer panel is folded over the inner panel. ACTION Repair corrosion at the hem flange using special hem flange tools. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE READ THIS REPAIR PROCEDURE COMPLETELY BEFORE PERFORMING ANY SERVICE ACTIONS. NOTE THE USE OF FORD OR MOTORCRAFT BRAND PRODUCTS ARE MANDATORY ON ALL REPAIR CLAIMS PAID BY FORD UNLESS OTHERWISE SPECIFIED IN EMISSIONS, SAFETY RECALLS, OWNER NOTIFICATION PROGRAMS, TSB'S OR OTHER COMPANY PUBLICATIONS. THE COST OF NON-FORD/MOTORCRAFT PRODUCTS USED FOR A WARRANTY, ESP/ESC OR AWA REPAIR WITHOUT JUSTIFYING THEIR USE (SUCH AS EMERGENCY REPAIR) IS NOT REIMBURSABLE. EXAMPLES OF FORD PRODUCTS ARE ADHESIVES, SEALERS, SOLVENTS, CLEANERS, WASHES, AND OTHER SPECIAL PRODUCTS LISTED IN THE FORD CAR CARE PRODUCTS MANUAL. NOTE TECHNICIANS SHOULD WEAR THE APPROPRIATE EYE, HAND AND HEARING PROTECTION WHILE PERFORMING THESE REPAIR PROCEDURES. ADHESIVES AND SEALERS USED IN THESE PROCEDURES SHOULD BE USED IN A WELL-VENTILATED AREA. 1. Inspect the inside of the door/tailgate at the lower edge only for corrosion/bubbling. 2. Follow the Workshop Manual procedure for the removal of the interior door panel or tailgate and tailgate moldings. 3. Use shop air to blow out the drain holes in the bottom of the door/tailgate and apply 25 mm (1") tape to the outer skin at the bottom to prevent scuffing. 4. Use a hammer and screwdriver to slightly lift the corner of the hem flange. 5. Insert TOOL 501-078/1(RT) or TOOL 501-078/2(LT) in an air impact gun (620 kPa (90 psi) air pressure is required for consistent tool operation). Using the tool lift the hem flange continuing across the bottom of the door/tailgate and stop just before the end. 6. Use an angle grinder or wire brush to remove all corrosion on the bottom of the hem flange and inner door/tailgate panel. Follow by blowing off with compressed air. 7. Using appropriate hand protection, brush on Corrosion Converter (Sem # 69508) on the corroded area. Use light coat and let flash dry 2-5 minutes. Follow by using a damp cloth to wipe off corrosion residue. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Tailgate > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-18-11 > Sep > 04 > Body - Corrosion At Bottom of Door or Tailgate > Page 11570 8. Sand with a DA sander using 360 grit sand paper the lower areas of the door/tailgate where paint was disturbed, keeping the repair area small. Feather edge for a paint blend as necessary. Blow off the panel with clean compressed air. Clean the panels with wax and remover. 9. Mix and brush on Ford approved epoxy or self-etching primer to all bare hem flange areas on the bottom of the door/tailgate. Bake at 140°F (60° C) panel temperature per manufacturers label instructions. 10. Install the Motorcraft TA-1 adhesive cartridge into the application gun 501-040. Squeeze out some material to purge the cartridge. Install the tip on the cartridge and squeeze out some material to make sure of even mixing of the adhesive components. 11. Apply the adhesive between the hem flange and bottom of the inner door/tailgate panel. Work time is 45 minutes at 70°F (21°C). Adhesive cure time is 8 hours. 12. Use TOOL 501-080 to re-hem (close down) the hem flange. Start in a corner, and insert the center of the tool over the area to close down and hit with a hammer. 13. Install the Motorcraft TA-2 urethane cartridge into the application gun 501-040. Squeeze out some material to purge the cartridge. Install the tip on the cartridge and squeeze out some material to make sure of even mixing of the adhesive components. 14. Apply Motorcraft TA-2 urethane seam sealer around the door/tailgate hem flange to give a finished appearance. 15. Remove any residual sealer with adhesive remover. Sealer is paintable in 10 minutes and within 24 hours. 16. Mask the door/tailgate for color application. 17. Mix and apply Ford approved basecoat color to the inside of the door/tailgate area and allow material to flash off. 18. Mix and apply Ford approved clearcoat to inside of the door/tailgate and bake at 140°F (60°C) panel temperature per following manufacturers recommended baking time. 19. Spray Dominion Sure Seal Amber anti corrosion coating (24011) to the inside of the door/tailgate at the hem location. Do not plug drain holes. 20. Demask the vehicle and, reinstall the inner door panel or tailgate moldings. SPECIAL TOOLS ^ 501-078/1 RH Hem Opening Tool (Tools are direct ship from O.T.C.) ^ 501-078/2 LH Hem Opening Tool ^ 501-080 Hem Closing Tool ^ 501-040 Adhesive Gun (Adhesive Gun not included in kits. This is a commonly used commercially available gun. Must be ordered separately from Rotunda.) PARTS BLOCK WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Tailgate > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tailgate: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Neck: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Tailgate > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tailgate: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 11576 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Tailgate > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tailgate: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 11577 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Tailgate > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tailgate: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 11578 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Tailgate > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tailgate: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 11579 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Tailgate > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tailgate: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 11580 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Tailgate > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tailgate: > 97-11-17 > May > 97 > Fuel System - Slow Fuel Filling/Early Nozzle Shut-Off Fuel Filler Neck: All Technical Service Bulletins Fuel System - Slow Fuel Filling/Early Nozzle Shut-Off Article No. 97-11-17 05/27/97 FUEL - SLOW FILL OR INABILITY TO PUMP GASOLINE INTO FILL NECK AT SERVICE STATIONS LIGHT TRUCK: 1997 EXPEDITION ISSUE: A slow fill or the inability to fill the fuel tank may be experienced on some vehicles. This may be a result of fuel pumps that have a flow rate that is too high, or nozzles that are not within SAE design standards. ACTION: Customer may back off the nozzle 12 mm (0.5") and fill normally. If not satisfied, the customer may have the fuel filler pipe replaced on vehicles built prior to March 26, 1997. The new fill pipe entry makes the design more tolerant of nozzles which do not follow the SAE standard. However, if a customer is using a nozzle that is not close to the SAE standard, then the customer may continue to have problems with early fuel shutoff, even with the new fuel fill pipe. Refer to the following Service Procedure for details. SERVICE PROCEDURE REMOVAL 1. Remove the Fuel Tank Filler Cap (-9030-). 2. Remove the fuel tank filler pipe screws. 3. Remove the filler pipe-to-floor panel screws. 4. Loosen the hose clamp and disconnect the fuel filler vent hose from the fuel tank filler pipe. 5. Disconnect and remove the fuel tank filler pipe. INSTALLATION 1. Connect the new Fuel Tank Filler Pipe (F75Z-9034-BF) and tighten the hose clamp to 3.9-6.3 N.m (34.5-56 lb-in). 2. Reconnect the fuel filler vent hose to the fuel tank filler pipe and tighten the hose clamp to 3.9-6.3 N.m (34.5-56 lb-in). 3. Install and tighten the filler pipe-to-floor panel screws to 7.6-10.4 N.m (67-92 lb-in). 4. Install and tighten the fuel tank filler pipe screws to 1.6-2.2 N.m (14-19.5 lb-in). 5. Replace the Fuel Tank Filler Cap (-9030-). PART NUMBER PART NAME F75Z-9034-BF Fuel Tank Filler Pipe OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971117A Replace Fuel Tank Filler 0.3 Hr. Pipe DEALER CODING CONDITION BASIC PART NO. CODE 9034 16 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Tailgate > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tailgate: > 97-11-17 > May > 97 > Fuel System - Slow Fuel Filling/Early Nozzle Shut-Off > Page 11585 OASIS CODES: 404000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Tailgate > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tailgate: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 11591 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Tailgate > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tailgate: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 11592 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Tailgate > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tailgate: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 11593 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Tailgate > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tailgate: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 11594 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Tailgate > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tailgate: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 11595 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Tailgate > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tailgate: > 97-11-17 > May > 97 > Fuel System - Slow Fuel Filling/Early Nozzle Shut-Off > Page 11600 OASIS CODES: 404000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems Technical Service Bulletin # 98-9-13 Date: 980511 Body/Frame - Water Leaks Causing Electrical Problems Article No. 98-9-13 05/11/98 ^ WATER LEAKS - VARIOUS AREAS OF VEHICLE ^ ELECTRICAL - ACCESSORIES FUNCTIONING IMPROPERLY DUE TO WATER LEAKS ^ LAMPS - WARNING LAMPS ILLUMINATED DUE TO WATER LEAKS LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR This TSB article is being republished in its entirety to add F-150, F-250 LD, and Navigator vehicles, and to revise the text and art accordingly. ISSUE Water leaks in various areas of the vehicle as identified below may be causing electrical concerns such as: ^ Warning lamps illuminating, and/or ^ Improper wiper operation, and/or ^ Improper function of electrical accessories The water leaks may be caused by sealer skips, unseated grommets, and/or clogged drain tubes. ACTION Repair the water leaks. Refer to the following Service Procedures for details on: ^ Windshield Leaks ^ Cowl Top Leaks ^ Cowl Side-to-Door Opening Panel Leaks ^ Cowl Side-to-Dash Panel Leaks ^ Moon roof Leaks ^ Grommets The following procedures may include using a seam sealer for repairs. Recommended seam sealers are: Company Part Name Phone Number 3M Ultrapro Seam Sealer (612) 733-5547 - US Kent Uniweld Seam Sealer (800) 654-6333 - US (800) 663-2800 - Canada OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-19-15 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11610 980913A Windshield Leaks Service 0.5 Hr. Procedure 980913B Additional Time If Leaf 0.4 Hr. Screen Must Be Removed (Used With Operation A) 980913C Cowl Top Leaks Service 1.3 Hrs. Procedure 980913D Cowl Side-To-Door 1.9 Hrs. Opening Panel Leaks Service Procedure 980913E Cowl Side-To-Dash Panel 0.4 Hr. Leaks Service Procedure 980913F Moonroof Leaks Service 0.4 Hr. Procedure 980913G Grommets Service 0.4 Hr. Procedure DEALER CODING CONDITION BASIC PART NO. CODE 18812 GROMMET(S) LEAKS 68 7801610 COWL TOP LEAKS (DASH PANEL) 68 7802012 COWL TOP LEAKS (OUTER) 68 7802018 COWL SIDE TO-DASH PANEL LEAKS 68 7802039 COWL SIDE-TO-DOOR OPENING PANEL LEAKS 68 7803100 WINDSHIELD LEAKS 68 78502C53 MOON ROOF LEAKS 68 OASIS CODES: 110000,190000, 202000, 203000, 205000, 206000 Windshield Leaks Service Procedure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11611 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11612 Refer To Figures 1, 2, and 3 1. Remove A-pillar mouldings, rocker panel scuff plates, and cowl lower scuff plates. Refer to the appropriate Workshop Manual, Section 501-05. 2. Apply a water hose at the bottom center of the windshield and slowly move outboard at a rate of 305 mm (1 foot) per 15-20 seconds. Then move up one side, inboard along top of header to the center. Lift the moulding at top of windshield to allow water to pass through windshield moulding. NOTE A NARROW NYLON TIP ON THE END OF THE HOSE WILL ALLOW THE OPERATOR TO EASILY SLIDE THE TIP UNDER THE MOULDING AND SLOWLY MOVE IT ALONG THE INSIDE SURFACE. 3. To determine if water is entering, have an observer use a flashlight to watch for water as the hose is being moved. The observer should start looking at the dash back panel by pulling back the dash insulator pad above the water location. 4. If a leak is detected, document the location and path for future reference. 5. Fill any voids with pumpable Butyl Sealer. NOTE TO REPAIR WATER LEAKS FOUND AT THE BASE OF THE WINDSHIELD, THE LEAF SCREEN MUST FIRST BE REMOVED. Cowl Top Leaks Service Procedure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11613 Refer To Figure 4 1. Remove the leaf screen by referring to the appropriate Workshop Manual, Section 501-02. 2. Spray water into cowl top-to-dash panel seam. Spray for up to 20 minutes. 3. Inspect the inner dash panel for water intrusion, starting at the bottom of the cowl area. 4. With the trim rocker cover and kick plate removed, pull back carpet and inspect for water. 5. If no water is found, look in the area of the cross car beam and/or lower windshield "VIN tag" area. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11614 6. Seal inner cowl with seam sealer. Cowl Side-to-Door Opening Panel Leaks Service Procedure Refer To Figure 5 1. Remove the left front tire. 2. Remove the inner fender splash shield from the left front fender. Refer to the appropriate Workshop Manual, Section 501-02, for details. 3. Remove the grille by referring to the Workshop Manual, Section 501-08. 4. Remove the left front fender by referring to the Workshop Manual, Section 501-02. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11615 5. Test with water. 6. Apply seam sealer along the interface between the cowl and the dash panel. This area can be reached through the access hole located near the top hinge for the front door. 7. Reassemble in reverse order. 8. Apply paint protection to fender bolts. Cowl Side-to-Dash Panel Leaks Service Procedure Refer To Figure 6 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11616 1. Remove rocker cover and lower scuff panel by referring to the appropriate Workshop Manual, Section 501-05. 2. Inspect dash panel-to-cowl side inner sealer for skips and/or missing sealer. 3. Test with water at the top of the cowl/leaf screen area and inspect the vehicle for water entry. 4. Apply seam sealer along the interface between the cowl, dash, and floor panel. Moonroof Leaks Service Procedure Refer To Figure 7 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11617 1. Before beginning any diagnosis, contact the Webasto Tech Hotline at (800) 995-5911 Monday-Friday, 9AM-6PM EST. 2. Cycle moonroof to open position. 3. Check for proper drain tube action by pouring approximately 1.8L (6 oz) of water into trough at each side. 4. If tubes appear to be draining properly, remove the interior A-pillar trim and sun visors. Refer to the appropriate Workshop Manual, Section 501-05. 5. Pull down the headliner slightly and inspect moonroof drain tubes for kinks and/or twists. The drain tubes must be free from any bends or obstruction of water flow. 6. Straighten or cut drain tubes to proper length to allow for free draining. Grommets Service Procedure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11618 Refer To Figure 8 1. Check for missing or improperly seated grommets in the following areas: ^ Antenna grommet on passenger side cowl ^ Park brake cable grommet on driver side cowl ^ Overall instrument panel grommets 2. Reseat any loose grommets or replace any missing grommets. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems Technical Service Bulletin # 98-9-13 Date: 980511 Body/Frame - Water Leaks Causing Electrical Problems Article No. 98-9-13 05/11/98 ^ WATER LEAKS - VARIOUS AREAS OF VEHICLE ^ ELECTRICAL - ACCESSORIES FUNCTIONING IMPROPERLY DUE TO WATER LEAKS ^ LAMPS - WARNING LAMPS ILLUMINATED DUE TO WATER LEAKS LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR This TSB article is being republished in its entirety to add F-150, F-250 LD, and Navigator vehicles, and to revise the text and art accordingly. ISSUE Water leaks in various areas of the vehicle as identified below may be causing electrical concerns such as: ^ Warning lamps illuminating, and/or ^ Improper wiper operation, and/or ^ Improper function of electrical accessories The water leaks may be caused by sealer skips, unseated grommets, and/or clogged drain tubes. ACTION Repair the water leaks. Refer to the following Service Procedures for details on: ^ Windshield Leaks ^ Cowl Top Leaks ^ Cowl Side-to-Door Opening Panel Leaks ^ Cowl Side-to-Dash Panel Leaks ^ Moon roof Leaks ^ Grommets The following procedures may include using a seam sealer for repairs. Recommended seam sealers are: Company Part Name Phone Number 3M Ultrapro Seam Sealer (612) 733-5547 - US Kent Uniweld Seam Sealer (800) 654-6333 - US (800) 663-2800 - Canada OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-19-15 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11624 980913A Windshield Leaks Service 0.5 Hr. Procedure 980913B Additional Time If Leaf 0.4 Hr. Screen Must Be Removed (Used With Operation A) 980913C Cowl Top Leaks Service 1.3 Hrs. Procedure 980913D Cowl Side-To-Door 1.9 Hrs. Opening Panel Leaks Service Procedure 980913E Cowl Side-To-Dash Panel 0.4 Hr. Leaks Service Procedure 980913F Moonroof Leaks Service 0.4 Hr. Procedure 980913G Grommets Service 0.4 Hr. Procedure DEALER CODING CONDITION BASIC PART NO. CODE 18812 GROMMET(S) LEAKS 68 7801610 COWL TOP LEAKS (DASH PANEL) 68 7802012 COWL TOP LEAKS (OUTER) 68 7802018 COWL SIDE TO-DASH PANEL LEAKS 68 7802039 COWL SIDE-TO-DOOR OPENING PANEL LEAKS 68 7803100 WINDSHIELD LEAKS 68 78502C53 MOON ROOF LEAKS 68 OASIS CODES: 110000,190000, 202000, 203000, 205000, 206000 Windshield Leaks Service Procedure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11625 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11626 Refer To Figures 1, 2, and 3 1. Remove A-pillar mouldings, rocker panel scuff plates, and cowl lower scuff plates. Refer to the appropriate Workshop Manual, Section 501-05. 2. Apply a water hose at the bottom center of the windshield and slowly move outboard at a rate of 305 mm (1 foot) per 15-20 seconds. Then move up one side, inboard along top of header to the center. Lift the moulding at top of windshield to allow water to pass through windshield moulding. NOTE A NARROW NYLON TIP ON THE END OF THE HOSE WILL ALLOW THE OPERATOR TO EASILY SLIDE THE TIP UNDER THE MOULDING AND SLOWLY MOVE IT ALONG THE INSIDE SURFACE. 3. To determine if water is entering, have an observer use a flashlight to watch for water as the hose is being moved. The observer should start looking at the dash back panel by pulling back the dash insulator pad above the water location. 4. If a leak is detected, document the location and path for future reference. 5. Fill any voids with pumpable Butyl Sealer. NOTE TO REPAIR WATER LEAKS FOUND AT THE BASE OF THE WINDSHIELD, THE LEAF SCREEN MUST FIRST BE REMOVED. Cowl Top Leaks Service Procedure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11627 Refer To Figure 4 1. Remove the leaf screen by referring to the appropriate Workshop Manual, Section 501-02. 2. Spray water into cowl top-to-dash panel seam. Spray for up to 20 minutes. 3. Inspect the inner dash panel for water intrusion, starting at the bottom of the cowl area. 4. With the trim rocker cover and kick plate removed, pull back carpet and inspect for water. 5. If no water is found, look in the area of the cross car beam and/or lower windshield "VIN tag" area. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11628 6. Seal inner cowl with seam sealer. Cowl Side-to-Door Opening Panel Leaks Service Procedure Refer To Figure 5 1. Remove the left front tire. 2. Remove the inner fender splash shield from the left front fender. Refer to the appropriate Workshop Manual, Section 501-02, for details. 3. Remove the grille by referring to the Workshop Manual, Section 501-08. 4. Remove the left front fender by referring to the Workshop Manual, Section 501-02. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11629 5. Test with water. 6. Apply seam sealer along the interface between the cowl and the dash panel. This area can be reached through the access hole located near the top hinge for the front door. 7. Reassemble in reverse order. 8. Apply paint protection to fender bolts. Cowl Side-to-Dash Panel Leaks Service Procedure Refer To Figure 6 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11630 1. Remove rocker cover and lower scuff panel by referring to the appropriate Workshop Manual, Section 501-05. 2. Inspect dash panel-to-cowl side inner sealer for skips and/or missing sealer. 3. Test with water at the top of the cowl/leaf screen area and inspect the vehicle for water entry. 4. Apply seam sealer along the interface between the cowl, dash, and floor panel. Moonroof Leaks Service Procedure Refer To Figure 7 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11631 1. Before beginning any diagnosis, contact the Webasto Tech Hotline at (800) 995-5911 Monday-Friday, 9AM-6PM EST. 2. Cycle moonroof to open position. 3. Check for proper drain tube action by pouring approximately 1.8L (6 oz) of water into trough at each side. 4. If tubes appear to be draining properly, remove the interior A-pillar trim and sun visors. Refer to the appropriate Workshop Manual, Section 501-05. 5. Pull down the headliner slightly and inspect moonroof drain tubes for kinks and/or twists. The drain tubes must be free from any bends or obstruction of water flow. 6. Straighten or cut drain tubes to proper length to allow for free draining. Grommets Service Procedure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 11632 Refer To Figure 8 1. Check for missing or improperly seated grommets in the following areas: ^ Antenna grommet on passenger side cowl ^ Park brake cable grommet on driver side cowl ^ Overall instrument panel grommets 2. Reseat any loose grommets or replace any missing grommets. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises Technical Service Bulletin # 99-6-5 Date: 990405 Side Doors - Wind Noises Article No. 99-6-5 04/05/99 WINDNOISE - AROUND SIDE DOOR(S) - SERVICE TIPS FORD: 1994-99 CROWN VICTORIA, ESCORT, TAURUS 1995-99 CONTOUR LINCOLN-MERCURY: 1994-98 MARK VIII 1994-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1994-97 F-150-350 SERIES 1994-99 ECONOLINE, EXPLORER, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, F-250 LD, MOUNTAINEER 1998-99 F-150, NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to add model year coverage and specify a standard door weatherstrip service push pin. ISSUE Windnoise from the side doors may be heard on some vehicles. This may be caused by the door weatherstrip seal. This TSB article provides Service Tips for correcting this concern. ACTION Diagnose and repair any windnoise from door weatherstrip concerns using the following Windnoise Service Tips. PART NUMBER PART NAME E8AZ-19552-A Weatherstrip And Rubber Adhesive E8AZ-19554-A Instant Adhesive N806340-S Snap-On Push Pin OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-18-5 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 110000, 701000 Windnoise Service Tips DO NOT REPLACE THE WEATHERSTRIP UNLESS IT IS: ^ Torn ^ Ripped ^ Cut ^ Deteriorated excessively ^ Material defect/abnormalities, or ^ TSB specifies the replacement of the weatherstrip Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 11641 NOTE REPLACEMENT SHOULD BE DUE TO NORMAL USE, NOT DUE TO CUSTOMER MISUSE. Weatherstrip Windnoise or Appearance Service Tips The following text explains attachment methods for Ford Motor Company's generic repair standards for loose and/or misaligned weatherstrips. Flanges are typically used on the body opening where weatherstrip retention fins grab onto each side of the sheet metal flange to retain the weatherstrip with a press fit. In cases where these weatherstrips become loose and/or misaligned, they can be reinstalled by pressing the locking retention fins back onto the sheet metal flange and stretching to provide better retention around corners. If the weatherstrip retention fins or metal carrier become damaged, it is also required that the U-section be carefully bent back into the proper shape to properly lock onto the sheet metal flange. Once replaced, check the weatherstrip for proper retention. If required, Weatherstrip and Rubber Adhesive (E8AZ-19552-A or equivalent meeting Ford specification ESB-M2G14-A) should be applied to the inside of the weatherstrip U-section to bond with the sheet metal flange for proper retention force. Sheet Metal C-Channels are typically used on the upper perimeter of the door assembly or body panel to hold the weatherstrip molded base inside the C-channel. In cases where these weatherstrips pop out of the channel, repair by first removing the weatherstrip from the entire channel, and reassemble by sliding the molded base back into the channel. If the sheet metal channel has been damaged, it is also required that the C-channel be carefully bent back into the proper shape to retain the weatherstrip molded base. Push Pins are typically used on the lower perimeter of the door assembly attached to the weatherstrip. They are press fit into sheet metal holes for retention. Push pins can be gently removed by pulling the actual pin normal to the surface, out of the hole, and reinserted without damage. If a push pin is damaged, it should be replaced by first removing the existing push pin. Then, the base of a new push pin should be inserted into the weatherstrip hole, and finally press fit into the corresponding sheet metal hole. All door perimeter weatherstrip push pins should be repaired using Ford standard N806340-S. Rivets are used to attach some weatherstrips to the sheet metal body. In cases where a rivet becomes loose, the entire rivet should be removed and replaced with a new rivet. Adhesive Tape is used to adhere smaller weatherstrip sections to the painted sheet metal surface. All surfaces must be clean and dry before any weatherstrip reattachment is performed. Adhesive tears should be reattached to the painted surface using general purpose Instant Adhesive (E8AZ-19554-A or equivalent). Verification 1. If the weatherstrip is not attached properly, reattach it correctly. 2. If the condition of the weatherstrip is good and it is attached properly, test drive the vehicle to diagnose the root cause of the windnoise. Verify the sealing contact between the door and the weatherstrip is sufficient with the 3X5" Card Test or a Chalk Test found in this TSB article. 3. If sealing contact between the weatherstrip and the door is the root cause of the windnoise, readjust the doors to contact the weatherstrips. NOTE WEATHERSTRIP REPAIRS SHOULD NOT CREATE UNACCEPTABLE DOOR CLOSING EFFORTS, WINDNOISE CONCERNS, OR WATER LEAK CONCERNS WITH THE DOOR SYSTEM. 3X5" Card Test 1. Insert a 3x5" card between the door and the weatherstrip at the base of the A-pillar with the door closed. 2. Run the card up along the A-pillar. If the card easily moves at any location along the A-pillar, then the sealing contact between the door and the weatherstrip is insufficient and the door should be adjusted to increase the sealing contact. This test can only be used to evaluate the A-pillar sealing contact at the margin. To evaluate sealing contact of the primary and secondary weatherstrips, a Chalk Test must be performed. Chalk Test 1. Lightly and evenly spray the sheet metal sealing surface of the door and body with a tracing powder (chalk spray). 2. Gently close the door, applying pressure only at the latch to prevent overslam (which will give an inaccurate reading). 3. Open the door and inspect the seals for degree of compression and possible skips. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 11642 To provide adequate sealing contact, the weatherstrip-to-sheet metal contact should provide a tracing powder footprint width of 4-6 mm on the weatherstrips. Any skips or tracing powder footprints less than 3mm in width indicate insufficient door-to-weatherstrip sealing contact and the door should be adjusted to increase the sealing contact. Door Adjusting Refer to Figures 1 and 2. 1. The upper and lower door hinges provide sufficient in/out adjustment to increase door contact with the dynamic weatherstrips. The door should not be pried or forced into alignment. To properly correct the door fit to the weatherstrips, the door striker and/or hinge bolts to the door must be loosened and adjusted to perform the alignment procedure. Note that the door striker only controls the in/out location of the door at the rear latch area. The hinges control the in/out location of the door at the front, and the overall tip or tilt of the door when viewed from the front or rear. 2. Review the overall fit of the door to the surrounding panels, and the amount of compression of the weatherstrip at all locations around the door. The fitting procedure is mastered sequentially from the rear of the vehicle to the front: ^ from the quarter panel to the rear door ^ from the rear door to the front door Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 11643 ^ then the front door to the fender All mating surfaces should be reviewed and, if necessary, refit starting with correcting the rear door to the quarter panel and working forward. 3. The door should be adjusted to obtain proper seal compression while maintaining a good door fit. An adjustment may be required only at one hinge. For example: if the top of the door is outboard, causing a lack of seal compression around the upper door frame area, and the fit of the lower part of the door is good to the adjacent panels, an inward adjustment at only the upper hinge would be appropriate (refer to Step 5). Note that adjustments to the rear door may require additional adjustments to the front door, and then also possibly to the front fender to maintain the proper panel fit and alignment. 4. The rear of the door should be set in/out with the striker to align at the door latch area with the mating panel. If the upper or lower part of the door doesn't align to the adjacent panel, the amount of door tip must be corrected by adjustment at the hinges in order to get both the upper and lower surfaces of the door aligned or flushed to the adjacent panels. 5. The in/out setting at the front of the doors is controlled by the hinge adjustment. ^ It should be set to obtain the proper amount of seal contact, which can be determined using the 3X5" Card Test or the Chalk Test. ^ As a guideline, if there is insufficient weatherstrip contact of the door, the hinge(s) should be adjusted 2-4 mm inboard. This is accomplished by loosening the hinge~to-door bolts just enough to permit movement of the door with a padded pry bar. ^ Only one hinge should be adjusted at a time. The other tight hinge helps to prevent any drastic door movement (which may result due to the weight of the door) which will result in a complete door refitting for both up/down as well as in/out positions. ^ The amount of movement can be determined by outlining the hinge mounting area on the door prior to adjustment, and measuring the hinge movement relative to this outline after adjustment. A 2-4mm adjustment should be sufficient to return the door to within its nominal operating range. 6. Finally, the door closing effort should be checked to be sure the seal compression has not increased so much that a closing effort concern has been created. If the efforts are unacceptably high, the door may have been moved excessively inward, and should be refitted outward to a location that balances the seal compression for windnoise with closing efforts. It may be necessary to perform another 3X5" Card Test or Chalk Test to verify the final seal compression. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 97-13-13 > Jun > 97 > Rear Quarter Window - Wind Noise Weatherstrip: Customer Interest Rear Quarter Window - Wind Noise Article No. 97-13-13 06/23/97 ^ WINDNOISE - REAR DOOR QUARTER WINDOW ^ NOISE - WINDNOISE AT REAR DOOR QUARTER WINDOW LIGHT TRUCK: 1997 EXPEDITION This TSB article is being republished in its entirety to revise the operation time. ISSUE: A windnoise may be heard at the rear door quarter window on some vehicles. This may be caused by the white locating clips of the quarter window not allowing the weatherstrip to properly seat. ACTION: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 97-13-13 > Jun > 97 > Rear Quarter Window - Wind Noise > Page 11648 Remove the rear door quarter window and remove 2 mm of the backside of the white locating clips next to the foam seal using metal shears or side cutters (Figure 1). This will reduce the possibility of windnoise by allowing the weatherstrip to seat properly. Refer to the 1997 Expedition Workshop Manual, Section 501-11, for quarter window removal and installation procedures. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-8-12 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971313AT Trim Locating Clips - Both 0.9 Hr. Doors 971313A Trim Locating Clip - One 0.6 Hr. Door DEALER CODING CONDITION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 97-13-13 > Jun > 97 > Rear Quarter Window - Wind Noise > Page 11649 BASIC PART NO. CODE 7820759 07 OASIS CODES: 102000, 701000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 97-13-14 > Jun > 97 > A Pillar - Wind Noise Weatherstrip: Customer Interest A Pillar - Wind Noise Article No. 97-13-14 06/23/97 WINDNOISE - AT A-PILLAR - VEHICLES BUILT BEFORE 3/24/97 LIGHT TRUCK: 1997 EXPEDITION ISSUE: Windnoise may be evident at the A-pillar on some vehicles. This may be caused by flock run at the edge of the door sheet metal flange sealing surface. ACTION: Place a butyl sealer (or equivalent meeting Ford specification ESB-M4G162-A) behind the flocked run at the top of the mirror sail panel. This should reduce the possibility of windnoise. Refer to the following Service Procedure for details. SERVICE PROCEDURE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 97-13-14 > Jun > 97 > A Pillar - Wind Noise > Page 11654 1. Remove the door inner sail panel by pulling the top of the panel to release the upper retention. Then rock the sail panel side-to-side along the door trim panel to release the panel from its lower mounting in the top of the door trim panel. 2. Roll the window down and pull back the flocking on the interior side of the run at the bend. 3. Install butyl (or equivalent) between the run and the edge of the door sheet metal. Best results can be achieved by rolling the butyl into a 6 mm (0.25") rope about 63 mm (2.5") long before installing. 4. Press flocking back into place and reinstall sail panel by installing the two lower pins and seating both sides and locate and seat the top pin in the sail panel. 5. Road test the vehicle. OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 97-13-14 > Jun > 97 > A Pillar - Wind Noise > Page 11655 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971314A Repair As Outlined 0.3 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 7821596 68 OASIS CODES: 102000, 701000, 702100 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 97812 > Apr > 97 > Rear Door Quarter Panel - Wind Noise Weatherstrip: Customer Interest Rear Door Quarter Panel - Wind Noise Article No. 97-8-12 04/14/97 ^ WINDNOISE - REAR DOOR QUARTER WINDOW ^ NOISE - WINDNOISE AT REAR DOOR QUARTER WINDOW LIGHT TRUCK: 1997 EXPEDITION ISSUE: A windnoise may be heard at the rear door quarter window on some vehicles. This may be caused by the white locating clips of the quarter window not allowing the weatherstrip to properly seat. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 97812 > Apr > 97 > Rear Door Quarter Panel - Wind Noise > Page 11660 ACTION: Remove the rear door quarter window and remove 2 mm of the backside of the white locating clips next to the foam seal using metal shears or side cutters (Figure 1). This will reduce the possibility of windnoise by allowing the weatherstrip to seat properly. Refer to the 1997 Expedition Workshop Manual, Section 501-11, for quarter window removal and installation procedures. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 970812AT Trim Locating Clips - Both Doors 0.6 Hr. 970812A Trim Locating Clip - One Door 0.6 Hr. DEALER CODING CONDITION BASIC PART NO. CODE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 97812 > Apr > 97 > Rear Door Quarter Panel - Wind Noise > Page 11661 7820759 57 OASIS CODES: 701000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises Technical Service Bulletin # 99-6-5 Date: 990405 Side Doors - Wind Noises Article No. 99-6-5 04/05/99 WINDNOISE - AROUND SIDE DOOR(S) - SERVICE TIPS FORD: 1994-99 CROWN VICTORIA, ESCORT, TAURUS 1995-99 CONTOUR LINCOLN-MERCURY: 1994-98 MARK VIII 1994-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1994-97 F-150-350 SERIES 1994-99 ECONOLINE, EXPLORER, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, F-250 LD, MOUNTAINEER 1998-99 F-150, NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to add model year coverage and specify a standard door weatherstrip service push pin. ISSUE Windnoise from the side doors may be heard on some vehicles. This may be caused by the door weatherstrip seal. This TSB article provides Service Tips for correcting this concern. ACTION Diagnose and repair any windnoise from door weatherstrip concerns using the following Windnoise Service Tips. PART NUMBER PART NAME E8AZ-19552-A Weatherstrip And Rubber Adhesive E8AZ-19554-A Instant Adhesive N806340-S Snap-On Push Pin OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-18-5 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 110000, 701000 Windnoise Service Tips DO NOT REPLACE THE WEATHERSTRIP UNLESS IT IS: ^ Torn ^ Ripped ^ Cut ^ Deteriorated excessively ^ Material defect/abnormalities, or ^ TSB specifies the replacement of the weatherstrip Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 11667 NOTE REPLACEMENT SHOULD BE DUE TO NORMAL USE, NOT DUE TO CUSTOMER MISUSE. Weatherstrip Windnoise or Appearance Service Tips The following text explains attachment methods for Ford Motor Company's generic repair standards for loose and/or misaligned weatherstrips. Flanges are typically used on the body opening where weatherstrip retention fins grab onto each side of the sheet metal flange to retain the weatherstrip with a press fit. In cases where these weatherstrips become loose and/or misaligned, they can be reinstalled by pressing the locking retention fins back onto the sheet metal flange and stretching to provide better retention around corners. If the weatherstrip retention fins or metal carrier become damaged, it is also required that the U-section be carefully bent back into the proper shape to properly lock onto the sheet metal flange. Once replaced, check the weatherstrip for proper retention. If required, Weatherstrip and Rubber Adhesive (E8AZ-19552-A or equivalent meeting Ford specification ESB-M2G14-A) should be applied to the inside of the weatherstrip U-section to bond with the sheet metal flange for proper retention force. Sheet Metal C-Channels are typically used on the upper perimeter of the door assembly or body panel to hold the weatherstrip molded base inside the C-channel. In cases where these weatherstrips pop out of the channel, repair by first removing the weatherstrip from the entire channel, and reassemble by sliding the molded base back into the channel. If the sheet metal channel has been damaged, it is also required that the C-channel be carefully bent back into the proper shape to retain the weatherstrip molded base. Push Pins are typically used on the lower perimeter of the door assembly attached to the weatherstrip. They are press fit into sheet metal holes for retention. Push pins can be gently removed by pulling the actual pin normal to the surface, out of the hole, and reinserted without damage. If a push pin is damaged, it should be replaced by first removing the existing push pin. Then, the base of a new push pin should be inserted into the weatherstrip hole, and finally press fit into the corresponding sheet metal hole. All door perimeter weatherstrip push pins should be repaired using Ford standard N806340-S. Rivets are used to attach some weatherstrips to the sheet metal body. In cases where a rivet becomes loose, the entire rivet should be removed and replaced with a new rivet. Adhesive Tape is used to adhere smaller weatherstrip sections to the painted sheet metal surface. All surfaces must be clean and dry before any weatherstrip reattachment is performed. Adhesive tears should be reattached to the painted surface using general purpose Instant Adhesive (E8AZ-19554-A or equivalent). Verification 1. If the weatherstrip is not attached properly, reattach it correctly. 2. If the condition of the weatherstrip is good and it is attached properly, test drive the vehicle to diagnose the root cause of the windnoise. Verify the sealing contact between the door and the weatherstrip is sufficient with the 3X5" Card Test or a Chalk Test found in this TSB article. 3. If sealing contact between the weatherstrip and the door is the root cause of the windnoise, readjust the doors to contact the weatherstrips. NOTE WEATHERSTRIP REPAIRS SHOULD NOT CREATE UNACCEPTABLE DOOR CLOSING EFFORTS, WINDNOISE CONCERNS, OR WATER LEAK CONCERNS WITH THE DOOR SYSTEM. 3X5" Card Test 1. Insert a 3x5" card between the door and the weatherstrip at the base of the A-pillar with the door closed. 2. Run the card up along the A-pillar. If the card easily moves at any location along the A-pillar, then the sealing contact between the door and the weatherstrip is insufficient and the door should be adjusted to increase the sealing contact. This test can only be used to evaluate the A-pillar sealing contact at the margin. To evaluate sealing contact of the primary and secondary weatherstrips, a Chalk Test must be performed. Chalk Test 1. Lightly and evenly spray the sheet metal sealing surface of the door and body with a tracing powder (chalk spray). 2. Gently close the door, applying pressure only at the latch to prevent overslam (which will give an inaccurate reading). 3. Open the door and inspect the seals for degree of compression and possible skips. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 11668 To provide adequate sealing contact, the weatherstrip-to-sheet metal contact should provide a tracing powder footprint width of 4-6 mm on the weatherstrips. Any skips or tracing powder footprints less than 3mm in width indicate insufficient door-to-weatherstrip sealing contact and the door should be adjusted to increase the sealing contact. Door Adjusting Refer to Figures 1 and 2. 1. The upper and lower door hinges provide sufficient in/out adjustment to increase door contact with the dynamic weatherstrips. The door should not be pried or forced into alignment. To properly correct the door fit to the weatherstrips, the door striker and/or hinge bolts to the door must be loosened and adjusted to perform the alignment procedure. Note that the door striker only controls the in/out location of the door at the rear latch area. The hinges control the in/out location of the door at the front, and the overall tip or tilt of the door when viewed from the front or rear. 2. Review the overall fit of the door to the surrounding panels, and the amount of compression of the weatherstrip at all locations around the door. The fitting procedure is mastered sequentially from the rear of the vehicle to the front: ^ from the quarter panel to the rear door ^ from the rear door to the front door Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 11669 ^ then the front door to the fender All mating surfaces should be reviewed and, if necessary, refit starting with correcting the rear door to the quarter panel and working forward. 3. The door should be adjusted to obtain proper seal compression while maintaining a good door fit. An adjustment may be required only at one hinge. For example: if the top of the door is outboard, causing a lack of seal compression around the upper door frame area, and the fit of the lower part of the door is good to the adjacent panels, an inward adjustment at only the upper hinge would be appropriate (refer to Step 5). Note that adjustments to the rear door may require additional adjustments to the front door, and then also possibly to the front fender to maintain the proper panel fit and alignment. 4. The rear of the door should be set in/out with the striker to align at the door latch area with the mating panel. If the upper or lower part of the door doesn't align to the adjacent panel, the amount of door tip must be corrected by adjustment at the hinges in order to get both the upper and lower surfaces of the door aligned or flushed to the adjacent panels. 5. The in/out setting at the front of the doors is controlled by the hinge adjustment. ^ It should be set to obtain the proper amount of seal contact, which can be determined using the 3X5" Card Test or the Chalk Test. ^ As a guideline, if there is insufficient weatherstrip contact of the door, the hinge(s) should be adjusted 2-4 mm inboard. This is accomplished by loosening the hinge~to-door bolts just enough to permit movement of the door with a padded pry bar. ^ Only one hinge should be adjusted at a time. The other tight hinge helps to prevent any drastic door movement (which may result due to the weight of the door) which will result in a complete door refitting for both up/down as well as in/out positions. ^ The amount of movement can be determined by outlining the hinge mounting area on the door prior to adjustment, and measuring the hinge movement relative to this outline after adjustment. A 2-4mm adjustment should be sufficient to return the door to within its nominal operating range. 6. Finally, the door closing effort should be checked to be sure the seal compression has not increased so much that a closing effort concern has been created. If the efforts are unacceptably high, the door may have been moved excessively inward, and should be refitted outward to a location that balances the seal compression for windnoise with closing efforts. It may be necessary to perform another 3X5" Card Test or Chalk Test to verify the final seal compression. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 97-13-13 > Jun > 97 > Rear Quarter Window - Wind Noise Weatherstrip: All Technical Service Bulletins Rear Quarter Window - Wind Noise Article No. 97-13-13 06/23/97 ^ WINDNOISE - REAR DOOR QUARTER WINDOW ^ NOISE - WINDNOISE AT REAR DOOR QUARTER WINDOW LIGHT TRUCK: 1997 EXPEDITION This TSB article is being republished in its entirety to revise the operation time. ISSUE: A windnoise may be heard at the rear door quarter window on some vehicles. This may be caused by the white locating clips of the quarter window not allowing the weatherstrip to properly seat. ACTION: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 97-13-13 > Jun > 97 > Rear Quarter Window - Wind Noise > Page 11674 Remove the rear door quarter window and remove 2 mm of the backside of the white locating clips next to the foam seal using metal shears or side cutters (Figure 1). This will reduce the possibility of windnoise by allowing the weatherstrip to seat properly. Refer to the 1997 Expedition Workshop Manual, Section 501-11, for quarter window removal and installation procedures. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-8-12 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971313AT Trim Locating Clips - Both 0.9 Hr. Doors 971313A Trim Locating Clip - One 0.6 Hr. Door DEALER CODING CONDITION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 97-13-13 > Jun > 97 > Rear Quarter Window - Wind Noise > Page 11675 BASIC PART NO. CODE 7820759 07 OASIS CODES: 102000, 701000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 97-13-14 > Jun > 97 > A Pillar - Wind Noise Weatherstrip: All Technical Service Bulletins A Pillar - Wind Noise Article No. 97-13-14 06/23/97 WINDNOISE - AT A-PILLAR - VEHICLES BUILT BEFORE 3/24/97 LIGHT TRUCK: 1997 EXPEDITION ISSUE: Windnoise may be evident at the A-pillar on some vehicles. This may be caused by flock run at the edge of the door sheet metal flange sealing surface. ACTION: Place a butyl sealer (or equivalent meeting Ford specification ESB-M4G162-A) behind the flocked run at the top of the mirror sail panel. This should reduce the possibility of windnoise. Refer to the following Service Procedure for details. SERVICE PROCEDURE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 97-13-14 > Jun > 97 > A Pillar - Wind Noise > Page 11680 1. Remove the door inner sail panel by pulling the top of the panel to release the upper retention. Then rock the sail panel side-to-side along the door trim panel to release the panel from its lower mounting in the top of the door trim panel. 2. Roll the window down and pull back the flocking on the interior side of the run at the bend. 3. Install butyl (or equivalent) between the run and the edge of the door sheet metal. Best results can be achieved by rolling the butyl into a 6 mm (0.25") rope about 63 mm (2.5") long before installing. 4. Press flocking back into place and reinstall sail panel by installing the two lower pins and seating both sides and locate and seat the top pin in the sail panel. 5. Road test the vehicle. OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 97-13-14 > Jun > 97 > A Pillar - Wind Noise > Page 11681 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971314A Repair As Outlined 0.3 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 7821596 68 OASIS CODES: 102000, 701000, 702100 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 97812 > Apr > 97 > Rear Door Quarter Panel - Wind Noise Weatherstrip: All Technical Service Bulletins Rear Door Quarter Panel - Wind Noise Article No. 97-8-12 04/14/97 ^ WINDNOISE - REAR DOOR QUARTER WINDOW ^ NOISE - WINDNOISE AT REAR DOOR QUARTER WINDOW LIGHT TRUCK: 1997 EXPEDITION ISSUE: A windnoise may be heard at the rear door quarter window on some vehicles. This may be caused by the white locating clips of the quarter window not allowing the weatherstrip to properly seat. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 97812 > Apr > 97 > Rear Door Quarter Panel - Wind Noise > Page 11686 ACTION: Remove the rear door quarter window and remove 2 mm of the backside of the white locating clips next to the foam seal using metal shears or side cutters (Figure 1). This will reduce the possibility of windnoise by allowing the weatherstrip to seat properly. Refer to the 1997 Expedition Workshop Manual, Section 501-11, for quarter window removal and installation procedures. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 970812AT Trim Locating Clips - Both Doors 0.6 Hr. 970812A Trim Locating Clip - One Door 0.6 Hr. DEALER CODING CONDITION BASIC PART NO. CODE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 97812 > Apr > 97 > Rear Door Quarter Panel - Wind Noise > Page 11687 7820759 57 OASIS CODES: 701000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11697 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11698 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11699 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11700 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11701 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11702 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11703 Attachment III - Technical Information Table of Contents Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11704 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11705 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11706 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11707 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11708 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11709 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11710 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11711 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11712 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11713 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11714 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11715 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11716 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11717 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11718 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11719 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11720 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11721 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11722 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): Recalls Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 11727 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Brake Switch (Cruise Control): Recalls Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11737 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11738 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11739 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11740 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11741 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11742 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11743 Attachment III - Technical Information Table of Contents Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11744 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11745 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11746 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11747 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11748 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11749 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11750 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11751 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11752 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11753 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11754 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11755 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11756 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11757 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11758 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11759 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11760 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11761 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11762 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): All Technical Service Bulletins Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 11767 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Brake Switch (Cruise Control): All Technical Service Bulletins Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 11772 Brake Switch (Cruise Control): Specifications Brake Pressure Switch ........................................................................................................................ ................................................ 15-20 Nm 11-14 Lb Ft Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 11773 Brake Switch (Cruise Control): Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the brake pressure switch electrical connector. 3. Remove the brake pressure switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive systems may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. NOTE: After the procedure is finished refer to brake bleeding procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Diagrams Speed Control Servo/Amplifier Assembly Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications Cruise Control Servo: Specifications Speed Control Servo Bracket Screws ............................................................................................................................................... 10-13 Nm 90-115 Lb In Speed Control Servo Bracket Bolts .................................................................................................................................................... 15-18 Nm 11-13 Lb Ft Speed Control Actuator to Cable Bracket Bolt ................................................................................................................................ 4.1-6.0 Nm 37-54 Lb In Accelerator Control Splash Shield Screws ....................................................................................................................................... 3.1-4.3 Nm 28-38 Lb In Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 11780 Speed Control Servo/Amplifier Assembly Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 11781 Cruise Control Servo: Service and Repair REMOVAL 1. Remove the accelerator control splash shield. 1. Remove the three screws. 2. Remove the accelerator control splash shield. 2. Remove the speed control actuator cable. - Lift the speed control actuator upward to remove. 3. Remove the speed control actuator cable to accelerator cable bracket bolt. 4. Push in locking arm on speed control actuator cable cap. Rotate cap counter clockwise and remove the speed control actuator cable cap from speed control servo. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 11782 5. Disconnect the speed control core wire end from speed control servo pulley. 1. Depress the spring retainer. 2. Slide core wire end out of the speed control servo pulley. 6. Disconnect the speed control servo electrical connector. 7. Remove the speed control servo and bracket. 1. Remove the two bolts. 2. Remove the speed control servo and bracket. 8. Remove the speed control servo bracket. 1. Remove the three screws. 2. Remove the speed control servo bracket. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 11783 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Adjustments Cruise Control Servo Cable: Adjustments 1. Remove the actuator cable clip. 2. Adjust the actuator cable. 1. Set the throttle body cam to the closed position. 2. Pull on the actuator cable to remove any slack. 3. Back off the actuator cable one notch. NOTE: The actuator cable must not be pulled tight for proper operation. 3. Hold the (A) speed control actuator cable and insert the (B) actuator clip securely. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Recalls for Cruise Control Switch: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Cruise Control Switch: Recalls Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Cruise Control Switch: All Technical Service Bulletins Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 11800 Cruise Control Switch: Service and Repair REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REMOVING AN AIR BAG. - CARRY A LIVE AIR BAG WITH THE BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. AN ACCIDENTAL DEPLOYMENT WILL THEN DEPLOY WITH A MINIMAL CHANCE OF INJURY. - PLACE A LIVE AIR BAG ON A BENCH OR OTHER SURFACE WITH THE TRIM COVER UP. - NEVER PROBE THE CONNECTORS ON THE AIR BAGS. DOING SO MAY RESULT IN AIR BAG DEPLOYMENT WHICH COULD RESULT IN PERSONAL INJURY. - TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REMOVING OR REPLACING ANY AIR BAG SYSTEM COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY TO STARTER CABLE AND WAIT ONE MINUTE. 1. Disconnect the battery cables. 1. Disconnect the battery ground cable. 2. Disconnect the battery to starter relay cable and wait one minute for the backup power supply to be depleted. 2. Remove the driver side air bag module. 1. Remove two air bag module screws. 2. Disconnect the air bag sliding contact electrical connector. 3. Disconnect the horn electrical connector. 4. Remove the driver side air bag module. WARNING: PLACE AIR BAG MODULE ON BENCH WITH TRIM COVER FACING UP. 3. Remove the speed control actuator switch. 1. Release the four (A) speed control actuator switch clips and (B) remove the speed control actuator switch 2. Disconnect the speed control actuator switch electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 11801 INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams Speed Control Servo/Amplifier Assembly Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11815 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11816 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11817 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11818 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11819 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11820 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11821 Attachment III - Technical Information Table of Contents Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11822 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11823 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11824 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11825 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11826 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11827 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11828 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11829 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11830 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11831 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11832 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11833 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11834 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11835 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11836 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11837 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11838 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11839 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11840 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): Recalls Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 11845 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Brake Switch (Cruise Control): Recalls Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11855 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11856 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11857 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11858 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11859 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11860 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11861 Attachment III - Technical Information Table of Contents Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11862 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11863 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11864 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11865 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11866 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11867 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11868 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11869 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11870 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11871 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11872 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11873 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11874 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11875 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11876 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11877 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11878 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11879 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 11880 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): All Technical Service Bulletins Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 11885 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Brake Switch (Cruise Control): All Technical Service Bulletins Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 11890 Brake Switch (Cruise Control): Specifications Brake Pressure Switch ........................................................................................................................ ................................................ 15-20 Nm 11-14 Lb Ft Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 11891 Brake Switch (Cruise Control): Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the brake pressure switch electrical connector. 3. Remove the brake pressure switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive systems may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. NOTE: After the procedure is finished refer to brake bleeding procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Recalls for Cruise Control Switch: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Cruise Control Switch: Recalls Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Cruise Control Switch: All Technical Service Bulletins Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 11905 Cruise Control Switch: Service and Repair REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REMOVING AN AIR BAG. - CARRY A LIVE AIR BAG WITH THE BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. AN ACCIDENTAL DEPLOYMENT WILL THEN DEPLOY WITH A MINIMAL CHANCE OF INJURY. - PLACE A LIVE AIR BAG ON A BENCH OR OTHER SURFACE WITH THE TRIM COVER UP. - NEVER PROBE THE CONNECTORS ON THE AIR BAGS. DOING SO MAY RESULT IN AIR BAG DEPLOYMENT WHICH COULD RESULT IN PERSONAL INJURY. - TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REMOVING OR REPLACING ANY AIR BAG SYSTEM COMPONENTS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY TO STARTER CABLE AND WAIT ONE MINUTE. 1. Disconnect the battery cables. 1. Disconnect the battery ground cable. 2. Disconnect the battery to starter relay cable and wait one minute for the backup power supply to be depleted. 2. Remove the driver side air bag module. 1. Remove two air bag module screws. 2. Disconnect the air bag sliding contact electrical connector. 3. Disconnect the horn electrical connector. 4. Remove the driver side air bag module. WARNING: PLACE AIR BAG MODULE ON BENCH WITH TRIM COVER FACING UP. 3. Remove the speed control actuator switch. 1. Release the four (A) speed control actuator switch clips and (B) remove the speed control actuator switch 2. Disconnect the speed control actuator switch electrical connector. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 11906 INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 11912 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 11913 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 11914 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 11915 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 11916 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 11917 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 11918 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 11919 Audible Warning Device: Electrical Diagrams Warning Chime (Part 1 Of 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 11920 Warning Chime (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Door Ajar Warning Chime Audible Warning Device: Description and Operation Door Ajar Warning Chime The door ajar warning chime warns that a door has become ajar. The door ajar warning chime is a single tone with a duration of one second. The chime will sound when the right front, right rear, left front, left rear, liftgate, or liftgate glass initially becomes ajar while the ignition switch is in the RUN position. The door ajar warning chime inputs are: - Ignition switch RUN position (battery potential on both RUN and RUN/ACC inputs). - Door open warning lamp switches (grounded when ajar, open circuit when closed). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Door Ajar Warning Chime > Page 11923 Audible Warning Device: Description and Operation Headlamps on Warning The headlamp warning chime warns that the headlamps are on when driver door is ajar. The headlamps warning chime will sound when all the following conditions are met: - Driver door is ajar. - Headlamp switch is in the PARK or HEAD position. - Ignition switch state is in the OFF/LOCK position. - Key-out. The headlamps warning chime will stop sounding when: - Any one of the conditions above are removed. The headlamps warning chime inputs are: - Ignition switch OFF/LOCK (open circuit on all ignition inputs). - Headlamp switch (battery potential when in PARK or HEAD position, open circuit when in OFF position). - LF door open warning lamp switch (open circuit with door closed, grounded with door ajar). - Key-in-ignition switch (grounded with key-in-ignition, open circuit with key-out). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Door Ajar Warning Chime > Page 11924 Audible Warning Device: Description and Operation Key-In-Ignition Warning The key-in-ignition chime warns that the key is still in the ignition when the driver door is ajar. The key-in-ignition warning chime will sound when: - Driver door is ajar, the ignition switch is in the OFF/LOCK or ACC position and the keys are in the ignition. The key-in-ignition warning chime will stop sounding when: - Driver door is closed. - Key is removed from the ignition. - Ignition switch is switched to the RUN position. The key-in-ignition warning chime inputs are: - Ignition switch RUN position (battery potential on both RUN and RUN/ACC inputs). - Ignition switch ACC position (battery potential on RUN/ACC input only). - Key-in-ignition switch (grounded with key-in-ignition, open circuit with key-out). - LF door open warning lamp switch (open circuit with door closed, grounded with door ajar). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Door Ajar Warning Chime > Page 11925 Audible Warning Device: Description and Operation Low Washer Fluid Warning Chime The low washer fluid warning chime warns that the washer fluid level is low. The low washer fluid warning chime is a single tone with a duration of one second. The chime will sound when the low washer fluid lamp is initially activated. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Door Ajar Warning Chime > Page 11926 Audible Warning Device: Description and Operation Door Ajar Warning Chime The door ajar warning chime warns that a door has become ajar. The door ajar warning chime is a single tone with a duration of one second. The chime will sound when the right front, right rear, left front, left rear, liftgate, or liftgate glass initially becomes ajar while the ignition switch is in the RUN position. The door ajar warning chime inputs are: - Ignition switch RUN position (battery potential on both RUN and RUN/ACC inputs). - Door open warning lamp switches (grounded when ajar, open circuit when closed). Headlamps on Warning The headlamp warning chime warns that the headlamps are on when driver door is ajar. The headlamps warning chime will sound when all the following conditions are met: - Driver door is ajar. - Headlamp switch is in the PARK or HEAD position. - Ignition switch state is in the OFF/LOCK position. - Key-out. The headlamps warning chime will stop sounding when: - Any one of the conditions above are removed. The headlamps warning chime inputs are: - Ignition switch OFF/LOCK (open circuit on all ignition inputs). - Headlamp switch (battery potential when in PARK or HEAD position, open circuit when in OFF position). - LF door open warning lamp switch (open circuit with door closed, grounded with door ajar). - Key-in-ignition switch (grounded with key-in-ignition, open circuit with key-out). Key-In-Ignition Warning The key-in-ignition chime warns that the key is still in the ignition when the driver door is ajar. The key-in-ignition warning chime will sound when: - Driver door is ajar, the ignition switch is in the OFF/LOCK or ACC position and the keys are in the ignition. The key-in-ignition warning chime will stop sounding when: - Driver door is closed. - Key is removed from the ignition. - Ignition switch is switched to the RUN position. The key-in-ignition warning chime inputs are: - Ignition switch RUN position (battery potential on both RUN and RUN/ACC inputs). - Ignition switch ACC position (battery potential on RUN/ACC input only). - Key-in-ignition switch (grounded with key-in-ignition, open circuit with key-out). - LF door open warning lamp switch (open circuit with door closed, grounded with door ajar). Low Washer Fluid Warning Chime The low washer fluid warning chime warns that the washer fluid level is low. The low washer fluid warning chime is a single tone with a duration of one second. The chime will sound when the low washer fluid lamp is initially activated. Safety Belt Warning The safety belt warning chime warns that the safety belt is not fastened. The safety belt warning chime will sound when: - The driver safety belt is not fastened and the ignition switch is turned from the OFF/LOCK or ACC to the RUN or START position. The safety belt warning chime will stop sounding when: - Safety belt fastened. - Ignition switch is switched from the RUN or START to the OFF/LOCK or ACC position. - After chime has sounded for six seconds. The safety belt warning chime inputs are: - Ignition switch START position (battery potential when in START position). - Ignition switch RUN position (battery potential on both the RUN and RUN/ACC inputs). - Driver safety belt switch (grounded when not fastened, open circuit when fastened). Warning Chime System The GEM controls the following warnings and chimes: - Driver safety belt not fastened warning (warning lamp and repetitive chime). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Door Ajar Warning Chime > Page 11927 - Key-in-ignition warning (repetitive chime). - Headlamp-on warning (repetitive chime). - Door ajar warning (warning lamp and single tone). - Low washer fluid warning (warning lamp and single tone). Four distinct chime rates are used to indicate warnings. They are: - Safety belt warning is one chime per second. - Key-in-ignition warning is two chimes per second. - Headlamp-on warning is four chimes per second. - Door ajar warning is a single tone. - Low washer fluid warning is a single tone. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis Audible Warning Device: Flow of Diagnosis 1. Verify the customer's original concern. 2. If the inspection reveals an obvious concern that can be readily identified, repair as required. 3. Before removing and installing the Generic Electronic Module (GEM) connectors, you must disconnect vehicle power at the battery. 4. If continuous DTCs are recorded and the symptom is not present when performing the pinpoint tests, an intermittent problem may be the cause. Always check for loose connections and corroded terminals when there is evidence of an intermittent problem. Complete the entire pinpoint test related to the symptom before replacing the GEM. 5. If the concern remains after the inspection, determine the symptoms and go to the Symptom Chart. See: Symptom Related Diagnostic Procedures 6. When probing the fuse junction panel, power distribution box or connectors, damage will result to the connector receptacle if you use a probe that is too large for the receptacle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11930 Audible Warning Device: Initial Inspection and Diagnostic Overview 1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical and electrical damage. Mechanical Damaged GEM. - Damaged key-in-ignition warning switch. - Damaged door open warning lamp switch. - Damaged safety belt warning indicator switch. Electrical Fuse(s). - Damaged wiring harness. - Loose or corroded connections Circuitry. 3. If the concern is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11931 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11932 Audible Warning Device: Symptom Related Diagnostic Procedures Symptom Chart (Part 1 Of 2) Symptom Chart (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11933 Audible Warning Device: Testing and Inspection Flow of Diagnosis 1. Verify the customer's original concern. 2. If the inspection reveals an obvious concern that can be readily identified, repair as required. 3. Before removing and installing the Generic Electronic Module (GEM) connectors, you must disconnect vehicle power at the battery. 4. If continuous DTCs are recorded and the symptom is not present when performing the pinpoint tests, an intermittent problem may be the cause. Always check for loose connections and corroded terminals when there is evidence of an intermittent problem. Complete the entire pinpoint test related to the symptom before replacing the GEM. 5. If the concern remains after the inspection, determine the symptoms and go to the Symptom Chart. See: Symptom Related Diagnostic Procedures 6. When probing the fuse junction panel, power distribution box or connectors, damage will result to the connector receptacle if you use a probe that is too large for the receptacle. Initial Inspection and Diagnostic Overview 1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical and electrical damage. Mechanical Damaged GEM. - Damaged key-in-ignition warning switch. - Damaged door open warning lamp switch. - Damaged safety belt warning indicator switch. Electrical Fuse(s). - Damaged wiring harness. - Loose or corroded connections Circuitry. 3. If the concern is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11934 Symptom Chart (Part 1 Of 2) Symptom Chart (Part 2 Of 2) Icons Used With Pinpoint Tests Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11935 Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. A: Safety Belt Chime & Warning Light Inop Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11936 A1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11937 A2-A3 A4-A5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11938 A6-A7 B: Safety Belt Warning Chime Is Inop Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11939 B1-B2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11940 B3-B4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11941 B5-B6 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11942 B7-B8 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11943 B9-B10 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11944 B11-B12 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11945 B13 C: Key-In-Ignition Chime Inop (LF Door Only) C1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11946 C2-C3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11947 C4-C5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11948 C6-C7 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11949 C8-C9 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11950 C10-C11 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11951 C12 D: Door Ajar Warning Inop (Single Chime & Lamp) D1 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11952 D2-D3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11953 D4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11954 D5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11955 D6 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11956 D7-D8 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11957 D9 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11958 D10-D11 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11959 D12-D14 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11960 D15-D16 E: Door Ajar Indicator Inop (Door Ajar Chime OK) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11961 E1-E2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11962 E3 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11963 E4-E5 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11964 E6-E7 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11965 E8-E9 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11966 E10-E11 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11967 E12-E13 F: No Chimes Operate Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11968 F1-F3 G: Headlamp ON Warning Chime Doesn't Operate Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11969 G1-G2 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11970 G3-G4 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11971 G5-G6 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11972 G7-G8 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11973 G9-G10 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11974 G11 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11975 G12-G13 Diagnostic Special Service Tool(s) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11976 Special Service Tool(s) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11977 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Testing and Inspection Brake Warning Indicator: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Charge Lamp/Indicator > Component Information > Testing and Inspection Charge Lamp/Indicator: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11988 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11989 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11990 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11991 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11992 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11993 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11994 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 11995 Horn/Cigar Lighter (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 11996 Cigarette Lighter: Description and Operation The cigar lighter: - Has a low resistance heating coil. The power point: - Supplies electrical current to external sources. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Directional Sensor > Component Information > Locations Directional Sensor: Locations Body View The Compass Sensor is located in the overhead console. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Directional Sensor > Component Information > Locations > Page 12001 Compass Sensor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming Deactivation Procedure 1. Disconnect positive battery cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Wait one minute. This is the time required for backup power supply in air bag diagnostic monitor to deplete its stored energy. 3. Remove two back cover plugs and remove screw and washer assemblies retaining driver side air bag module to steering wheel. Disconnect horn electrical connector. Disconnect driver air bag sliding contact electrical connector. Remove driver side air bag module from vehicle. WARNING: Place air bag module on bench with trim cover facing up. 4. Connect Rotunda Air Bag Simulator 105-R0011 or equivalent to vehicle harness at top of steering column. 5. Remove passenger side air bag module. Install Rotunda Air Bag Simulator 105-00012 or equivalent on vehicle harness connector in place of passenger side air bag module. 6. Reconnect positive battery cable. Reactivation Procedure 1. Disconnect positive battery cable. WARNING: The air bag simulator must be removed and the air bag reconnected when the system is reactivated. 2. Wait one minute for backup power supply in air bag diagnostic monitor to deplete stored energy. 3. Remove air bag simulator from vehicle harness connector at top of steering column. 4. Reconnect driver side air bag module. 5. Position driver side air bag module on steering wheel and secure with two screw and washer assemblies (8 mm). Tighten screw and washer assemblies to 10-13 Nm (89-115 lb in). Install two back cover plugs. 6. Remove air bag simulator from vehicle harness connector on passenger side. Reconnect and install passenger side air bag module. 7. Reconnect positive battery cable. 8. Prove out system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 12007 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The check list below should be completed following diagnosis or service of any air bag system concern: 1. Are both air bag crash sensors connected and mounted to the vehicle? 2. Is 3-way connector at base of steering column connected? 3. Are the air bags or air bag simulators connected? 4. Is air bag diagnostic monitor connected? 5. Is vehicle battery connected? Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Description and Operation Dimmer Switch: Description and Operation The panel dimmer switch is integrated into the headlamp switch and controls the interior lamps by activating the interior lamp relay. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Description and Operation Door/Trunk Ajar Indicator/Lamp: Description and Operation The GEM controls the Door ajar warning lamp. The door ajar warning lamp warns that a door is ajar. The door ajar warning lamp illuminates when it is grounded. The door ajar warning lamp will be illuminated when: - Any door, the liftgate, or liftgate glass initially becomes ajar while the ignition switch is in the RUN or START position. The door ajar warning lamp will turn off when: - All doors, the liftgate glass, and the liftgate are closed. - The ignition switch is turned to the OFF/LOCK or ACC position. The door ajar warning lamp inputs are: - Ignition switch START position (battery potential when in START). - Ignition switch RUN position (battery potential on both RUN and RUN/ACC inputs). - Door open warning lamp switches (grounded with door ajar, open circuit with door closed). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Description and Operation > Page 12014 Door/Trunk Ajar Indicator/Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Testing and Inspection Four Wheel Drive Indicator Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly Technical Service Bulletin # 97B17 Date: 980201 Campaign - Fuel Gauge/Sender Assembly 97517 OWNER NOTIFICATION PROGRAM Fuel Gauge/Sender Assembly Replacement Original - February, 1998 Dealer Letter Attachment I ^ Administrative Information ^ Refund Codes Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Supplement # 1 - April, 1998 Supplement # 2 - November, 1998 Revised Expiration Date For Owner Notification Program 98B17 - Fuel Gauge/sender Replacement ^ IMPORTANT INFORMATION OWNER NOTIFICATION PROGRAM 97B17 EXPIRATION DATE ^ Attachments not Applicable ^ Customer Notification Letter not Applicable Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12026 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Affected vehicles on the enclosed list. ^ Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12027 Enter claims using DWE. See ACESII Manual, Sections 5 and 6. OWNER REFUNDS See ACESII Manual, Section 3-63 for submission procedures. For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Program Code - 97B17 Misc. Expense - REFUND Misc. Expense - ADMIN. Misc. Expense - 0.2 Hr. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order fuel sender assemblies and the gaskets through normal processing channels. PART NUMBER/DESCRIPTION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12028 Fuel Sender Assembly - NOTE: Some of the following applications will require gaskets to be ordered in addition to the sender assemblies. DEALER PRICE For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. CLAIMS PREPARATION Enter using DWE. Use code information shown below: ^ Program Code - 97B17 ^ Labor Operation Code - See Above See Sections 5 and 6 of the ACESII Manual for detailed instructions Affected Vehicle and Warning Information AFFECTED VEHICLES: CERTAIN 1997 TAURUS/SABLE, EXPLORER/MOUNTAINEER, EXPEDITION, MUSTANG AND 1998 WINDSTAR WARNING DO NOT SWALLOW GASOLINE, THESE FUELS ARE HIGHLY TOXIC AND IF SWALLOWED CAN CAUSE DEATH OR PERMANENT INJURY, SWALLOWING METHANOL CAN ALSO CAUSE BLINDNESS. CALL A PHYSICIAN IMMEDIATELY TO TREAT ANYONE WHO HAS SWALLOWED FUEL METHANOL OR FUEL ETHANOL. VOMITING SHOULD BE INDUCED BY OR UNDER THE DIRECTION OF A PHYSICIAN OR POISON CONTROL CENTER. BE AWARE THAT THE ONSET OF POTENTIAL ILL HEALTH EFFECTS MAY BE DELAYED. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12029 WARNING AVOID INHALING FUEL VAPORS. INHALING TOO MUCH FUEL VAPOR CAN LEAD TO EYE AND RESPIRATORY TRACT IRRITATION. IN SEVERE CASES, EXCESSIVE OR PROLONGED BREATHING OF FUEL VAPORS CAN CAUSE SERIOUS ILLNESS AND PERMANENT INJURY SUCH AS BLINDNESS. WARNING AVOID GETTING GASOLINE IN YOUR EYES. IF YOU GET ANY FUEL IN YOUR EYES, REMOVE CONTRACT LENSES (IF WORN), FLUSH IMMEDIATELY WITH PLENTY OF WATER FOR AT LEAST 15 MINUTES AND SEEK MEDICAL ATTENTION. WARNING IF YOU GET ANY FUEL ON YOUR SKIN, WASH WITH SOAP AND WATER. REPEATED OR PROLONGED SKIN CONTACT WITH FUEL LIQUID OR VAPOR CAUSES SKIN IRRITATION. WARNING DO NOT OPERATE ENGINE OR SMOKE WHILE REFUELING. Expedition 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Raise and support vehicle. 4. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 5. Disconnect fuel filler and vent hoses from fuel tank. Refer to Figure 1. 6. Disconnect rear EVAP hose from top of fuel tank. See Figure 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12030 7. Support fuel tank with adjustable jack. 8. Remove fuel tank straps retaining bolts. The skid plate, fuel tank and straps will be removed as an assembly. 9. Slightly lower fuel tank. 10. Disconnect fuel supply and return lines from top of fuel tank. See Figure 2. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12031 11. Disconnect fuel pump electrical connector, located between the side of the fuel tank and the frame rail. See Figure 3. 12. Slightly lower fuel tank again. 13. Disconnect front EVAP hose from top of fuel tank. 14. Remove fuel tank from vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12032 15. Clean area around fuel pump to prevent foreign material from entering fuel tank. Refer to Figure 4. 16. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel pump during reassembly. 17. Remove fuel pump lock-ring, then remove fuel pump. See Figure 4. 18. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12033 19. Disconnect fuel sender electrical connectors. Refer to Figure 5. 20. Remove fuel sender retaining screws, then remove fuel sender. See Figure 5. 21. Install new fuel sender on fuel pump. Tighten screws to 2 Nm (18 lb/in). 22. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 23. Clean fuel pump-to-gas tank mating surface. 24. Install new seal onto fuel pump-to-gas tank mating surface. 25. Install fuel pump. Align marks made during disassembly. Tighten lock-ring to 44 Nm (33 lb/ft). 26. Position fuel tank under vehicle. 27. Raise fuel tank enough to connect front EVAP hose. 28. Connect front EVAP hose. 29. Raise fuel tank enough to connect fuel lines. 30. Connect fuel supply and return lines. 31. Connect fuel pump electrical connector. 32. Raise fuel tank to installed position. 33. Install fuel tank strap retaining bolts. Tighten bolts to 46-63 Nm (33-46 lb/ft). 34. Remove jack. 35. Connect rear EVAP hose to top of fuel tank. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12034 36. Connect fuel filler and vent hoses to fuel tank. 37. Refill fuel tank. It may be necessary to refill fuel tank before connecting filler hose. 38. Lower vehicle. 39. Connect battery negative cable, then remove memory saver. 40. Stan and run engine. 41. Raise vehicle. 42. Inspect fuel system for leaks. 43. Lower vehicle. Explorer/Mountaineer 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Raise and support vehicle. 4. Remove skid plate retaining bolts, then the skid plate. 5. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 6. Support fuel tank with adjustable jack. 7. Disconnect fuel filler and vent hoses from fuel tank. 8. Remove fuel tank strap retaining bolt. 9. Remove fuel tank-to-front support bracket retaining bolts. 10. Slightly lower fuel tank. Push fuel tank back until lip of tank clears support bracket. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12035 11. Disconnect fuel supply, return and vapor lines from top of fuel tank. See Figure 6. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12036 12. Disconnect fuel pump electrical connector, located in frame rail. See Figure 7. 13. Remove fuel tank from vehicle. 14. Disconnect fuel tank pressure transducer electrical connector. Refer to Figure 8. 15. Clean area around fuel pump to prevent foreign material from entering fuel tank. 16. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel pump during assembly. 17. Remove fuel pump retaining screws, then remove fuel pump. See Figure 8. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12037 18. Disconnect fuel sender electrical connectors. Refer to Figure 9. 19. Remove fuel sender retaining screws, then remove fuel sender. See Figure 9. 20. Install new fuel sender on fuel pump. Tighten screws to 2 Nm (18 lb/in). 21. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 22. Clean fuel pump-to-gas tank mating surface. 23. Install fuel pump. Align marks made during disassembly. Tighten retaining screws to 9-12 Nm (80-107 lb/in). 24. Connect fuel tank pressure transducer electrical connector. 25. Position fuel tank under vehicle. 26. Raise fuel tank enough to connect fuel lines. 27. Connect fuel supply and return lines. 28. Connect fuel pump electrical connector. 29. Position fuel tank in installed position. 30. Install fuel tank-to-front support bracket retaining bolts. Tighten bolts to 34-46 Nm (25-34 lb/ft). 31. Install fuel tank strap retaining bolt. Tighten bolts to 34-46 Nm (25-34 lb/ft). 32. Remove jack. 33. Connect fuel filler and vent hoses to fuel tank. 34. Install skid plate. Torque retaining bolts to 34-46 Nm (25-34 lb/ft). 35. Lower vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12038 36. Fill fuel tank. 37. Connect battery negative cable, then remove memory saver. 38. Start and run engine. 39. Raise vehicle. 40. Inspect fuel system for leaks. 41. Lower vehicle. Mustang 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 4. Remove fuel filler pipe retainers from gas cap side of fuel filler pipe. 5. Raise and support vehicle. 6. Remove screw retaining fuel filler pipe retainer to fuel tank flange.Refer to Figure 10. 7. Remove fuel filler pipe rubber weather boot from inner fender well. See Figure 10. 8. Support fuel tank with adjustable jack. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12039 9. Disconnect fuel pump electrical connector. See Figure 11. 10. Remove fuel tank straps retaining bolts. 11. Slightly lower fuel tank. 12. With an assistant's help, remove filler pipe from fuel tank. The filler pipe is friction fit into the fuel tank, the filler pipe will have to be walked out of the fuel tank. See Figure 12. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12040 13. Disconnect fuel supply, return and vapor lines. See Figure 13. 14. Disconnect fuel sender electrical connector. Refer to Figure 14. 15. Remove fuel tank from vehicle. 16. Clean area around fuel sender to prevent foreign material from entering fuel tank. 17. Place alignment mark across fuel sender and fuel tank. This will assure correct alignment of fuel sender during assembly. 18. Remove fuel sender lock-ring. See Figure 14. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12041 19. Remove and discard fuel sender. 20. Remove and discard fuel sender seal. 21. Lubricate and install new fuel sender seal. 22. Install new fuel sender. Align mark made during disassembly. Tighten lock ring until it contact stops. 23. Connect fuel sender electrical connector. 24. Raise fuel tank enough to connect fuel lines. 25. Connect fuel supply, return and vapor lines. 26. Install fuel filler pipe in fuel tank. 27. Position fuel tank in installed position. 28. Install fuel tank straps. Tighten retaining bolts to 30-40 Nm (22-30 lb/ft). 29. Remove adjustable jack. 30. Connect fuel pump electrical connector. 31. Install fuel filler pipe rubber weather boot to inner fender well. 32. Install screw retaining fuel filler pipe retainer to fuel tank flange. Tighten screw to 7.3-9.0 Nm (65-80 lb/in). 33. Lower vehicle. 34. Install fuel filler pipe retainers to gas cap side of fuel filler pipe. 35. Fill fuel tank. 36. Connect battery negative cable, then remove memory saver. 37. Start and run engine. 38. Raise vehicle. 39. Inspect fuel system for leaks. 40. Lower vehicle. Taurus/Sable 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 4. Raise and support vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12042 5. Disconnect fuel filler and vent hoses from fuel tank. See Figure 15. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12043 6. Disconnect fuel supply and return lines. Refer to Figure 16. 7. Disconnect fuel pump electrical connector. See Figure 16. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12044 8. Disconnect fuel vapor line. See Figure 17. 9. Support fuel tank with adjustable jack. 10. Remove fuel tank strap retaining bolts. 11. Remove fuel tank from vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12045 12. Detach fuel pump wiring harness and fuel lines from fuel tank. Refer to Figure 18. 13. Clean area around fuel pump to prevent foreign material from entering fuel tank. 14. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel pump during assembly. 15. Disconnect fuel pressure transducer electrical connector. See Figure 18. 16. Remove fuel pump lock-ring. 17. Remove fuel pump. 18. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12046 19. Disconnect fuel sender electrical connectors. Refer to Figure 19. 20. Remove fuel sender retaining screw, then remove fuel sender. See Figure 19. 21. Install new fuel sender on fuel pump. Tighten screw to 1 Nm (9 lb/in). 22. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 23. Clean fuel pump-to-gas tank mating surface. 24. Lubricate and install new fuel pump gasket. 25. Install fuel pump. Align marks made during disassembly. Tighten lock ring until it contacts stops. 26. Install fuel pump wiring harness and fuel lines on fuel tank assembly. 27. Connect fuel pressure transducer electrical connector. 28. Install fuel tank in vehicle. Tighten fuel tank straps to 30-40 Nm (22-30 lb/ft). 29. Remove adjustable jack. 30. Connect fuel pump electrical connector. 31. Connect fuel supply, return and vapor lines. 32. Connect fuel filler and vent hoses to fuel tank. 33. Lower vehicle. 34. Fill fuel tank. 35. Connect battery negative cable, then remove memory saver. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12047 36. Start and run engine. 37. Raise vehicle. 38. Inspect fuel system for leaks. 39. Lower vehicle. Windstar 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 4. Raise and support vehicle. 5. Support fuel tank with adjustable jack. 6. Disconnect fuel filler and vent hoses from fuel tank. 7. Disconnect fuel supply, return and vapor lines. See Figure 20. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12048 8. Disconnect fuel pump electrical connector. See Figure 21. 9. Remove fuel tank straps retaining bolts. 10. Remove fuel tank from vehicle. 11. Clean area around fuel pump to prevent foreign material from entering fuel tank. 12. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel during assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12049 13. Detach fuel lines from routing clips and tie strap. See Figure 22. 14. Remove fuel pump lock-ring. 15. Remove fuel pump. 16. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12050 17. Disconnect fuel sender electrical connectors. Refer to Figure 23. 18. Remove fuel sender retaining screw, then remove fuel sender. See Figure 23. 19. Install new fuel sender on fuel pump. Tighten screw to 1 Nm (9 lb/in). 20. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 21. Clean fuel pump-to-gas tank mating surface. 22. Install new fuel pump gasket. 23. Install fuel pump. Align marks made during disassembly. Tighten lock ring until it contact stops. 24. Attach fuel lines to routing clips and install tie strap. Connect fuel lines to fuel pump. Connect electrical connector to pump/sender. 25. Install fuel tank in vehicle. Tighten fuel tank straps to 41-54 Nm (31-39 lb/ft). 26. Connect fuel pump electrical connector. 27. Connect fuel supply, return and vapor lines. 28. Connect fuel filler and vent hoses to fuel tank. 29. Remove adjustable jack. 30. Lower vehicle. 31. Fill fuel tank. 32. Connect battery negative cable, then remove memory saver. 33. Start and run engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12051 34. Raise vehicle. 35. Inspect fuel system for leaks. 36. Lower vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12052 Supplement # 1 - Attachment II LABOR ALLOWANCES Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12053 PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order fuel sender assemblies and the gaskets through normal processing channels. PART NUMBER/DESCRIPTION Fuel Sender Assembly - NOTE: Some of the following applications will require gaskets to be ordered in addition to the sender assemblies. NOTE: Kit Codes "AA" & "BB" are not used. Warning For 1997 Expedition FUEL SENDER REPLACEMENT SUPPLEMENT FOR 1997 EXPEDITION WARNING DO NOT SWALLOW GASOLINE, THESE FUELS ARE HIGHLY TOXIC AND IF SWALLOWED CAN CAUSE DEATH OR PERMANENT INJURY, SWALLOWING METHANOL CAN ALSO CAUSE BLINDNESS. CALL A PHYSICIAN IMMEDIATELY TO TREAT ANYONE WHO HAS SWALLOWED FUEL METHANOL OR FUEL ETHANOL. VOMITING SHOULD BE INDUCED BY OR UNDER THE DIRECTION OF A PHYSICIAN OR POISON CONTROL CENTER. BE AWARE THAT THE ONSET OF POTENTIAL ILL HEALTH EFFECTS MAY BE DELAYED. WARNING AVOID INHALING FUEL VAPORS. INHALING TOO MUCH FUEL VAPOR CAN LEAD TO EYE AND RESPIRATORY TRACT IRRITATION. IN SEVERE CASES, EXCESSIVE OR PROLONGED BREATHING OF FUEL VAPORS CAN CAUSE SERIOUS ILLNESS AND PERMANENT INJURY SUCH AS BLINDNESS. WARNING AVOID GETTING GASOLINE IN YOUR EYES. IF YOU GET ANY FUEL IN YOUR EYES, REMOVE CONTACT LENSES (IF WORN), FLUSH IMMEDIATELY WITH PLENTY OF WATER FOR AT LEAST 15 MINUTES AND SEEK MEDICAL ATTENTION. WARNING IF YOU GET ANY FUEL ON YOUR SKIN, WASH WITH SOAP AND WATER. REPEATED OR PROLONGED SKIN CONTACT WITH FUEL LIQUID OR VAPOR CAUSES SKIN IRRITATION. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12054 WARNING DO NOT OPERATE ENGINE OR SMOKE WHILE REFUELING. Expedition 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Raise and support vehicle. 4. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 5. Disconnect fuel filler and vent hoses from fuel tank. Refer to Figure 1. 6. Disconnect rear EVAP hose from top of fuel tank. See Figure 1. 7. Support fuel tank with adjustable jack. 8. Remove fuel tank straps retaining bolts. The skid plate, fuel tank and straps will be removed as an assembly. 9. Slightly lower fuel tank. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12055 10. Disconnect fuel supply and return lines from top of fuel tank. See Figure 2. 11. Disconnect fuel pump electrical connector, located between the side of the fuel tank and the frame rail. See Figure 3. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12056 12. Slightly lower fuel tank again. 13. Disconnect front EVAP hose from top of fuel tank. 14. Remove fuel tank from vehicle. 15. Clean area around fuel pump to prevent foreign material from entering fuel tank. Refer to Figure 4. 16. Place alignment mark across fuel pump and fuel tank. This will correctly align the fuel pump during reassembly. 17. Remove fuel pump lock-ring, then remove fuel pump. See Figure 4. 18. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12057 19. Disconnect fuel sender electrical connectors. Refer to Figure 5. 20. Remove fuel sender retaining screws, then remove fuel sender. See Figure 5. NOTE: On some vehicles this step may have already been performed. CAUTION Do not cut the main 14 gauge pump ground wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12058 21. Cut a section out of the 18 gauge black grounding wire. See Figure 6. Discard removed black wire. 22. Install new fuel sender on the fuel pump. Tighten screws to 2 Nm (18 lb/in). Note the revised orientation of the float. NOTE: There are two (2) different terminal end types used on the fuel sender ground wire, a box terminal or a ring terminal. These terminal ends are connected to different locations on the fuel sender. 23. Connect fuel sender electrical connectors as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12059 ^ Connect box type terminal end ground wire to location shown in Figure 7. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12060 ^ Connect ring type terminal end ground wire to location shown in Figure 8. ^ Reconnect yellow wire to pump sending unit harness. 24. Clean fuel pump-to-gas tank mating surface. 25. Install new seal onto fuel pump-to-gas tank mating surface. 26. Install fuel pump. Align marks made during disassembly. Tighten lock-ring to 44 Nm (33 lb/ft). 27. Position fuel tank under vehicle. 28. Raise fuel tank enough to connect front EVAP hose. 29. Connect front EVAP hose. 30. Raise fuel tank enough to connect fuel lines. 31. Connect fuel supply and return lines. 32. Connect fuel pump electrical connector. 33. Raise fuel tank to installed position. 34. Install fuel tank strap retaining bolts. Tighten bolts to 46-63 Nm (33-46 lb/ft). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Recalls for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12061 35. Remove jack. 36. Connect rear EVAP hose to top of fuel tank. 37. Connect fuel filler and vent hoses to fuel tank. 38. Refill fuel tank. It may be necessary to refill fuel tank before connecting filler hose. 39. Lower vehicle. 40. Connect battery negative cable, then remove memory saver. 41. Stan and run engine. 42. Raise vehicle. 43. Inspect fuel system for leaks. 44. Lower vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly Technical Service Bulletin # 97B17 Date: 980201 Campaign - Fuel Gauge/Sender Assembly 97517 OWNER NOTIFICATION PROGRAM Fuel Gauge/Sender Assembly Replacement Original - February, 1998 Dealer Letter Attachment I ^ Administrative Information ^ Refund Codes Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Supplement # 1 - April, 1998 Supplement # 2 - November, 1998 Revised Expiration Date For Owner Notification Program 98B17 - Fuel Gauge/sender Replacement ^ IMPORTANT INFORMATION OWNER NOTIFICATION PROGRAM 97B17 EXPIRATION DATE ^ Attachments not Applicable ^ Customer Notification Letter not Applicable Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12067 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Affected vehicles on the enclosed list. ^ Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12068 Enter claims using DWE. See ACESII Manual, Sections 5 and 6. OWNER REFUNDS See ACESII Manual, Section 3-63 for submission procedures. For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Program Code - 97B17 Misc. Expense - REFUND Misc. Expense - ADMIN. Misc. Expense - 0.2 Hr. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order fuel sender assemblies and the gaskets through normal processing channels. PART NUMBER/DESCRIPTION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12069 Fuel Sender Assembly - NOTE: Some of the following applications will require gaskets to be ordered in addition to the sender assemblies. DEALER PRICE For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. CLAIMS PREPARATION Enter using DWE. Use code information shown below: ^ Program Code - 97B17 ^ Labor Operation Code - See Above See Sections 5 and 6 of the ACESII Manual for detailed instructions Affected Vehicle and Warning Information AFFECTED VEHICLES: CERTAIN 1997 TAURUS/SABLE, EXPLORER/MOUNTAINEER, EXPEDITION, MUSTANG AND 1998 WINDSTAR WARNING DO NOT SWALLOW GASOLINE, THESE FUELS ARE HIGHLY TOXIC AND IF SWALLOWED CAN CAUSE DEATH OR PERMANENT INJURY, SWALLOWING METHANOL CAN ALSO CAUSE BLINDNESS. CALL A PHYSICIAN IMMEDIATELY TO TREAT ANYONE WHO HAS SWALLOWED FUEL METHANOL OR FUEL ETHANOL. VOMITING SHOULD BE INDUCED BY OR UNDER THE DIRECTION OF A PHYSICIAN OR POISON CONTROL CENTER. BE AWARE THAT THE ONSET OF POTENTIAL ILL HEALTH EFFECTS MAY BE DELAYED. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12070 WARNING AVOID INHALING FUEL VAPORS. INHALING TOO MUCH FUEL VAPOR CAN LEAD TO EYE AND RESPIRATORY TRACT IRRITATION. IN SEVERE CASES, EXCESSIVE OR PROLONGED BREATHING OF FUEL VAPORS CAN CAUSE SERIOUS ILLNESS AND PERMANENT INJURY SUCH AS BLINDNESS. WARNING AVOID GETTING GASOLINE IN YOUR EYES. IF YOU GET ANY FUEL IN YOUR EYES, REMOVE CONTRACT LENSES (IF WORN), FLUSH IMMEDIATELY WITH PLENTY OF WATER FOR AT LEAST 15 MINUTES AND SEEK MEDICAL ATTENTION. WARNING IF YOU GET ANY FUEL ON YOUR SKIN, WASH WITH SOAP AND WATER. REPEATED OR PROLONGED SKIN CONTACT WITH FUEL LIQUID OR VAPOR CAUSES SKIN IRRITATION. WARNING DO NOT OPERATE ENGINE OR SMOKE WHILE REFUELING. Expedition 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Raise and support vehicle. 4. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 5. Disconnect fuel filler and vent hoses from fuel tank. Refer to Figure 1. 6. Disconnect rear EVAP hose from top of fuel tank. See Figure 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12071 7. Support fuel tank with adjustable jack. 8. Remove fuel tank straps retaining bolts. The skid plate, fuel tank and straps will be removed as an assembly. 9. Slightly lower fuel tank. 10. Disconnect fuel supply and return lines from top of fuel tank. See Figure 2. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12072 11. Disconnect fuel pump electrical connector, located between the side of the fuel tank and the frame rail. See Figure 3. 12. Slightly lower fuel tank again. 13. Disconnect front EVAP hose from top of fuel tank. 14. Remove fuel tank from vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12073 15. Clean area around fuel pump to prevent foreign material from entering fuel tank. Refer to Figure 4. 16. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel pump during reassembly. 17. Remove fuel pump lock-ring, then remove fuel pump. See Figure 4. 18. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12074 19. Disconnect fuel sender electrical connectors. Refer to Figure 5. 20. Remove fuel sender retaining screws, then remove fuel sender. See Figure 5. 21. Install new fuel sender on fuel pump. Tighten screws to 2 Nm (18 lb/in). 22. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 23. Clean fuel pump-to-gas tank mating surface. 24. Install new seal onto fuel pump-to-gas tank mating surface. 25. Install fuel pump. Align marks made during disassembly. Tighten lock-ring to 44 Nm (33 lb/ft). 26. Position fuel tank under vehicle. 27. Raise fuel tank enough to connect front EVAP hose. 28. Connect front EVAP hose. 29. Raise fuel tank enough to connect fuel lines. 30. Connect fuel supply and return lines. 31. Connect fuel pump electrical connector. 32. Raise fuel tank to installed position. 33. Install fuel tank strap retaining bolts. Tighten bolts to 46-63 Nm (33-46 lb/ft). 34. Remove jack. 35. Connect rear EVAP hose to top of fuel tank. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12075 36. Connect fuel filler and vent hoses to fuel tank. 37. Refill fuel tank. It may be necessary to refill fuel tank before connecting filler hose. 38. Lower vehicle. 39. Connect battery negative cable, then remove memory saver. 40. Stan and run engine. 41. Raise vehicle. 42. Inspect fuel system for leaks. 43. Lower vehicle. Explorer/Mountaineer 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Raise and support vehicle. 4. Remove skid plate retaining bolts, then the skid plate. 5. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 6. Support fuel tank with adjustable jack. 7. Disconnect fuel filler and vent hoses from fuel tank. 8. Remove fuel tank strap retaining bolt. 9. Remove fuel tank-to-front support bracket retaining bolts. 10. Slightly lower fuel tank. Push fuel tank back until lip of tank clears support bracket. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12076 11. Disconnect fuel supply, return and vapor lines from top of fuel tank. See Figure 6. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12077 12. Disconnect fuel pump electrical connector, located in frame rail. See Figure 7. 13. Remove fuel tank from vehicle. 14. Disconnect fuel tank pressure transducer electrical connector. Refer to Figure 8. 15. Clean area around fuel pump to prevent foreign material from entering fuel tank. 16. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel pump during assembly. 17. Remove fuel pump retaining screws, then remove fuel pump. See Figure 8. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12078 18. Disconnect fuel sender electrical connectors. Refer to Figure 9. 19. Remove fuel sender retaining screws, then remove fuel sender. See Figure 9. 20. Install new fuel sender on fuel pump. Tighten screws to 2 Nm (18 lb/in). 21. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 22. Clean fuel pump-to-gas tank mating surface. 23. Install fuel pump. Align marks made during disassembly. Tighten retaining screws to 9-12 Nm (80-107 lb/in). 24. Connect fuel tank pressure transducer electrical connector. 25. Position fuel tank under vehicle. 26. Raise fuel tank enough to connect fuel lines. 27. Connect fuel supply and return lines. 28. Connect fuel pump electrical connector. 29. Position fuel tank in installed position. 30. Install fuel tank-to-front support bracket retaining bolts. Tighten bolts to 34-46 Nm (25-34 lb/ft). 31. Install fuel tank strap retaining bolt. Tighten bolts to 34-46 Nm (25-34 lb/ft). 32. Remove jack. 33. Connect fuel filler and vent hoses to fuel tank. 34. Install skid plate. Torque retaining bolts to 34-46 Nm (25-34 lb/ft). 35. Lower vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12079 36. Fill fuel tank. 37. Connect battery negative cable, then remove memory saver. 38. Start and run engine. 39. Raise vehicle. 40. Inspect fuel system for leaks. 41. Lower vehicle. Mustang 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 4. Remove fuel filler pipe retainers from gas cap side of fuel filler pipe. 5. Raise and support vehicle. 6. Remove screw retaining fuel filler pipe retainer to fuel tank flange.Refer to Figure 10. 7. Remove fuel filler pipe rubber weather boot from inner fender well. See Figure 10. 8. Support fuel tank with adjustable jack. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12080 9. Disconnect fuel pump electrical connector. See Figure 11. 10. Remove fuel tank straps retaining bolts. 11. Slightly lower fuel tank. 12. With an assistant's help, remove filler pipe from fuel tank. The filler pipe is friction fit into the fuel tank, the filler pipe will have to be walked out of the fuel tank. See Figure 12. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12081 13. Disconnect fuel supply, return and vapor lines. See Figure 13. 14. Disconnect fuel sender electrical connector. Refer to Figure 14. 15. Remove fuel tank from vehicle. 16. Clean area around fuel sender to prevent foreign material from entering fuel tank. 17. Place alignment mark across fuel sender and fuel tank. This will assure correct alignment of fuel sender during assembly. 18. Remove fuel sender lock-ring. See Figure 14. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12082 19. Remove and discard fuel sender. 20. Remove and discard fuel sender seal. 21. Lubricate and install new fuel sender seal. 22. Install new fuel sender. Align mark made during disassembly. Tighten lock ring until it contact stops. 23. Connect fuel sender electrical connector. 24. Raise fuel tank enough to connect fuel lines. 25. Connect fuel supply, return and vapor lines. 26. Install fuel filler pipe in fuel tank. 27. Position fuel tank in installed position. 28. Install fuel tank straps. Tighten retaining bolts to 30-40 Nm (22-30 lb/ft). 29. Remove adjustable jack. 30. Connect fuel pump electrical connector. 31. Install fuel filler pipe rubber weather boot to inner fender well. 32. Install screw retaining fuel filler pipe retainer to fuel tank flange. Tighten screw to 7.3-9.0 Nm (65-80 lb/in). 33. Lower vehicle. 34. Install fuel filler pipe retainers to gas cap side of fuel filler pipe. 35. Fill fuel tank. 36. Connect battery negative cable, then remove memory saver. 37. Start and run engine. 38. Raise vehicle. 39. Inspect fuel system for leaks. 40. Lower vehicle. Taurus/Sable 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 4. Raise and support vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12083 5. Disconnect fuel filler and vent hoses from fuel tank. See Figure 15. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12084 6. Disconnect fuel supply and return lines. Refer to Figure 16. 7. Disconnect fuel pump electrical connector. See Figure 16. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12085 8. Disconnect fuel vapor line. See Figure 17. 9. Support fuel tank with adjustable jack. 10. Remove fuel tank strap retaining bolts. 11. Remove fuel tank from vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12086 12. Detach fuel pump wiring harness and fuel lines from fuel tank. Refer to Figure 18. 13. Clean area around fuel pump to prevent foreign material from entering fuel tank. 14. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel pump during assembly. 15. Disconnect fuel pressure transducer electrical connector. See Figure 18. 16. Remove fuel pump lock-ring. 17. Remove fuel pump. 18. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12087 19. Disconnect fuel sender electrical connectors. Refer to Figure 19. 20. Remove fuel sender retaining screw, then remove fuel sender. See Figure 19. 21. Install new fuel sender on fuel pump. Tighten screw to 1 Nm (9 lb/in). 22. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 23. Clean fuel pump-to-gas tank mating surface. 24. Lubricate and install new fuel pump gasket. 25. Install fuel pump. Align marks made during disassembly. Tighten lock ring until it contacts stops. 26. Install fuel pump wiring harness and fuel lines on fuel tank assembly. 27. Connect fuel pressure transducer electrical connector. 28. Install fuel tank in vehicle. Tighten fuel tank straps to 30-40 Nm (22-30 lb/ft). 29. Remove adjustable jack. 30. Connect fuel pump electrical connector. 31. Connect fuel supply, return and vapor lines. 32. Connect fuel filler and vent hoses to fuel tank. 33. Lower vehicle. 34. Fill fuel tank. 35. Connect battery negative cable, then remove memory saver. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12088 36. Start and run engine. 37. Raise vehicle. 38. Inspect fuel system for leaks. 39. Lower vehicle. Windstar 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 4. Raise and support vehicle. 5. Support fuel tank with adjustable jack. 6. Disconnect fuel filler and vent hoses from fuel tank. 7. Disconnect fuel supply, return and vapor lines. See Figure 20. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12089 8. Disconnect fuel pump electrical connector. See Figure 21. 9. Remove fuel tank straps retaining bolts. 10. Remove fuel tank from vehicle. 11. Clean area around fuel pump to prevent foreign material from entering fuel tank. 12. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel during assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12090 13. Detach fuel lines from routing clips and tie strap. See Figure 22. 14. Remove fuel pump lock-ring. 15. Remove fuel pump. 16. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12091 17. Disconnect fuel sender electrical connectors. Refer to Figure 23. 18. Remove fuel sender retaining screw, then remove fuel sender. See Figure 23. 19. Install new fuel sender on fuel pump. Tighten screw to 1 Nm (9 lb/in). 20. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 21. Clean fuel pump-to-gas tank mating surface. 22. Install new fuel pump gasket. 23. Install fuel pump. Align marks made during disassembly. Tighten lock ring until it contact stops. 24. Attach fuel lines to routing clips and install tie strap. Connect fuel lines to fuel pump. Connect electrical connector to pump/sender. 25. Install fuel tank in vehicle. Tighten fuel tank straps to 41-54 Nm (31-39 lb/ft). 26. Connect fuel pump electrical connector. 27. Connect fuel supply, return and vapor lines. 28. Connect fuel filler and vent hoses to fuel tank. 29. Remove adjustable jack. 30. Lower vehicle. 31. Fill fuel tank. 32. Connect battery negative cable, then remove memory saver. 33. Start and run engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12092 34. Raise vehicle. 35. Inspect fuel system for leaks. 36. Lower vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12093 Supplement # 1 - Attachment II LABOR ALLOWANCES Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12094 PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order fuel sender assemblies and the gaskets through normal processing channels. PART NUMBER/DESCRIPTION Fuel Sender Assembly - NOTE: Some of the following applications will require gaskets to be ordered in addition to the sender assemblies. NOTE: Kit Codes "AA" & "BB" are not used. Warning For 1997 Expedition FUEL SENDER REPLACEMENT SUPPLEMENT FOR 1997 EXPEDITION WARNING DO NOT SWALLOW GASOLINE, THESE FUELS ARE HIGHLY TOXIC AND IF SWALLOWED CAN CAUSE DEATH OR PERMANENT INJURY, SWALLOWING METHANOL CAN ALSO CAUSE BLINDNESS. CALL A PHYSICIAN IMMEDIATELY TO TREAT ANYONE WHO HAS SWALLOWED FUEL METHANOL OR FUEL ETHANOL. VOMITING SHOULD BE INDUCED BY OR UNDER THE DIRECTION OF A PHYSICIAN OR POISON CONTROL CENTER. BE AWARE THAT THE ONSET OF POTENTIAL ILL HEALTH EFFECTS MAY BE DELAYED. WARNING AVOID INHALING FUEL VAPORS. INHALING TOO MUCH FUEL VAPOR CAN LEAD TO EYE AND RESPIRATORY TRACT IRRITATION. IN SEVERE CASES, EXCESSIVE OR PROLONGED BREATHING OF FUEL VAPORS CAN CAUSE SERIOUS ILLNESS AND PERMANENT INJURY SUCH AS BLINDNESS. WARNING AVOID GETTING GASOLINE IN YOUR EYES. IF YOU GET ANY FUEL IN YOUR EYES, REMOVE CONTACT LENSES (IF WORN), FLUSH IMMEDIATELY WITH PLENTY OF WATER FOR AT LEAST 15 MINUTES AND SEEK MEDICAL ATTENTION. WARNING IF YOU GET ANY FUEL ON YOUR SKIN, WASH WITH SOAP AND WATER. REPEATED OR PROLONGED SKIN CONTACT WITH FUEL LIQUID OR VAPOR CAUSES SKIN IRRITATION. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12095 WARNING DO NOT OPERATE ENGINE OR SMOKE WHILE REFUELING. Expedition 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Raise and support vehicle. 4. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 5. Disconnect fuel filler and vent hoses from fuel tank. Refer to Figure 1. 6. Disconnect rear EVAP hose from top of fuel tank. See Figure 1. 7. Support fuel tank with adjustable jack. 8. Remove fuel tank straps retaining bolts. The skid plate, fuel tank and straps will be removed as an assembly. 9. Slightly lower fuel tank. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12096 10. Disconnect fuel supply and return lines from top of fuel tank. See Figure 2. 11. Disconnect fuel pump electrical connector, located between the side of the fuel tank and the frame rail. See Figure 3. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12097 12. Slightly lower fuel tank again. 13. Disconnect front EVAP hose from top of fuel tank. 14. Remove fuel tank from vehicle. 15. Clean area around fuel pump to prevent foreign material from entering fuel tank. Refer to Figure 4. 16. Place alignment mark across fuel pump and fuel tank. This will correctly align the fuel pump during reassembly. 17. Remove fuel pump lock-ring, then remove fuel pump. See Figure 4. 18. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12098 19. Disconnect fuel sender electrical connectors. Refer to Figure 5. 20. Remove fuel sender retaining screws, then remove fuel sender. See Figure 5. NOTE: On some vehicles this step may have already been performed. CAUTION Do not cut the main 14 gauge pump ground wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12099 21. Cut a section out of the 18 gauge black grounding wire. See Figure 6. Discard removed black wire. 22. Install new fuel sender on the fuel pump. Tighten screws to 2 Nm (18 lb/in). Note the revised orientation of the float. NOTE: There are two (2) different terminal end types used on the fuel sender ground wire, a box terminal or a ring terminal. These terminal ends are connected to different locations on the fuel sender. 23. Connect fuel sender electrical connectors as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12100 ^ Connect box type terminal end ground wire to location shown in Figure 7. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12101 ^ Connect ring type terminal end ground wire to location shown in Figure 8. ^ Reconnect yellow wire to pump sending unit harness. 24. Clean fuel pump-to-gas tank mating surface. 25. Install new seal onto fuel pump-to-gas tank mating surface. 26. Install fuel pump. Align marks made during disassembly. Tighten lock-ring to 44 Nm (33 lb/ft). 27. Position fuel tank under vehicle. 28. Raise fuel tank enough to connect front EVAP hose. 29. Connect front EVAP hose. 30. Raise fuel tank enough to connect fuel lines. 31. Connect fuel supply and return lines. 32. Connect fuel pump electrical connector. 33. Raise fuel tank to installed position. 34. Install fuel tank strap retaining bolts. Tighten bolts to 46-63 Nm (33-46 lb/ft). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12102 35. Remove jack. 36. Connect rear EVAP hose to top of fuel tank. 37. Connect fuel filler and vent hoses to fuel tank. 38. Refill fuel tank. It may be necessary to refill fuel tank before connecting filler hose. 39. Lower vehicle. 40. Connect battery negative cable, then remove memory saver. 41. Stan and run engine. 42. Raise vehicle. 43. Inspect fuel system for leaks. 44. Lower vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Testing and Inspection > Pinpoint Tests Fuel Gauge: Pinpoint Tests For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Testing and Inspection > Pinpoint Tests > Page 12105 Fuel Gauge: Component Tests and General Diagnostics Preliminary Setup 1. Disconnect the fuel level sensor and pump C415. Connect one lead of the tester to fuel level sensor and pump C415-8, circuit 29 (Y/W), and the other lead to ground. 2. Set the tester to 22.4 ohms. Key ON. Wait one minute. The fuel gauge should indicate E (empty). Key OFF. 3. Set the tester to 145 ohms. Key ON. Wait one minute. The fuel gauge should indicate F (full). Key OFF. Return to the pinpoint test. See: Instrument Cluster / Carrier/Testing and Inspection/Pinpoint Tests/C: Fuel Level Reads Inaccurately Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly Technical Service Bulletin # 97B17 Date: 980201 Campaign - Fuel Gauge/Sender Assembly 97517 OWNER NOTIFICATION PROGRAM Fuel Gauge/Sender Assembly Replacement Original - February, 1998 Dealer Letter Attachment I ^ Administrative Information ^ Refund Codes Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Supplement # 1 - April, 1998 Supplement # 2 - November, 1998 Revised Expiration Date For Owner Notification Program 98B17 - Fuel Gauge/sender Replacement ^ IMPORTANT INFORMATION OWNER NOTIFICATION PROGRAM 97B17 EXPIRATION DATE ^ Attachments not Applicable ^ Customer Notification Letter not Applicable Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12114 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Affected vehicles on the enclosed list. ^ Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12115 Enter claims using DWE. See ACESII Manual, Sections 5 and 6. OWNER REFUNDS See ACESII Manual, Section 3-63 for submission procedures. For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Program Code - 97B17 Misc. Expense - REFUND Misc. Expense - ADMIN. Misc. Expense - 0.2 Hr. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order fuel sender assemblies and the gaskets through normal processing channels. PART NUMBER/DESCRIPTION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12116 Fuel Sender Assembly - NOTE: Some of the following applications will require gaskets to be ordered in addition to the sender assemblies. DEALER PRICE For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. CLAIMS PREPARATION Enter using DWE. Use code information shown below: ^ Program Code - 97B17 ^ Labor Operation Code - See Above See Sections 5 and 6 of the ACESII Manual for detailed instructions Affected Vehicle and Warning Information AFFECTED VEHICLES: CERTAIN 1997 TAURUS/SABLE, EXPLORER/MOUNTAINEER, EXPEDITION, MUSTANG AND 1998 WINDSTAR WARNING DO NOT SWALLOW GASOLINE, THESE FUELS ARE HIGHLY TOXIC AND IF SWALLOWED CAN CAUSE DEATH OR PERMANENT INJURY, SWALLOWING METHANOL CAN ALSO CAUSE BLINDNESS. CALL A PHYSICIAN IMMEDIATELY TO TREAT ANYONE WHO HAS SWALLOWED FUEL METHANOL OR FUEL ETHANOL. VOMITING SHOULD BE INDUCED BY OR UNDER THE DIRECTION OF A PHYSICIAN OR POISON CONTROL CENTER. BE AWARE THAT THE ONSET OF POTENTIAL ILL HEALTH EFFECTS MAY BE DELAYED. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12117 WARNING AVOID INHALING FUEL VAPORS. INHALING TOO MUCH FUEL VAPOR CAN LEAD TO EYE AND RESPIRATORY TRACT IRRITATION. IN SEVERE CASES, EXCESSIVE OR PROLONGED BREATHING OF FUEL VAPORS CAN CAUSE SERIOUS ILLNESS AND PERMANENT INJURY SUCH AS BLINDNESS. WARNING AVOID GETTING GASOLINE IN YOUR EYES. IF YOU GET ANY FUEL IN YOUR EYES, REMOVE CONTRACT LENSES (IF WORN), FLUSH IMMEDIATELY WITH PLENTY OF WATER FOR AT LEAST 15 MINUTES AND SEEK MEDICAL ATTENTION. WARNING IF YOU GET ANY FUEL ON YOUR SKIN, WASH WITH SOAP AND WATER. REPEATED OR PROLONGED SKIN CONTACT WITH FUEL LIQUID OR VAPOR CAUSES SKIN IRRITATION. WARNING DO NOT OPERATE ENGINE OR SMOKE WHILE REFUELING. Expedition 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Raise and support vehicle. 4. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 5. Disconnect fuel filler and vent hoses from fuel tank. Refer to Figure 1. 6. Disconnect rear EVAP hose from top of fuel tank. See Figure 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12118 7. Support fuel tank with adjustable jack. 8. Remove fuel tank straps retaining bolts. The skid plate, fuel tank and straps will be removed as an assembly. 9. Slightly lower fuel tank. 10. Disconnect fuel supply and return lines from top of fuel tank. See Figure 2. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12119 11. Disconnect fuel pump electrical connector, located between the side of the fuel tank and the frame rail. See Figure 3. 12. Slightly lower fuel tank again. 13. Disconnect front EVAP hose from top of fuel tank. 14. Remove fuel tank from vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12120 15. Clean area around fuel pump to prevent foreign material from entering fuel tank. Refer to Figure 4. 16. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel pump during reassembly. 17. Remove fuel pump lock-ring, then remove fuel pump. See Figure 4. 18. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12121 19. Disconnect fuel sender electrical connectors. Refer to Figure 5. 20. Remove fuel sender retaining screws, then remove fuel sender. See Figure 5. 21. Install new fuel sender on fuel pump. Tighten screws to 2 Nm (18 lb/in). 22. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 23. Clean fuel pump-to-gas tank mating surface. 24. Install new seal onto fuel pump-to-gas tank mating surface. 25. Install fuel pump. Align marks made during disassembly. Tighten lock-ring to 44 Nm (33 lb/ft). 26. Position fuel tank under vehicle. 27. Raise fuel tank enough to connect front EVAP hose. 28. Connect front EVAP hose. 29. Raise fuel tank enough to connect fuel lines. 30. Connect fuel supply and return lines. 31. Connect fuel pump electrical connector. 32. Raise fuel tank to installed position. 33. Install fuel tank strap retaining bolts. Tighten bolts to 46-63 Nm (33-46 lb/ft). 34. Remove jack. 35. Connect rear EVAP hose to top of fuel tank. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12122 36. Connect fuel filler and vent hoses to fuel tank. 37. Refill fuel tank. It may be necessary to refill fuel tank before connecting filler hose. 38. Lower vehicle. 39. Connect battery negative cable, then remove memory saver. 40. Stan and run engine. 41. Raise vehicle. 42. Inspect fuel system for leaks. 43. Lower vehicle. Explorer/Mountaineer 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Raise and support vehicle. 4. Remove skid plate retaining bolts, then the skid plate. 5. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 6. Support fuel tank with adjustable jack. 7. Disconnect fuel filler and vent hoses from fuel tank. 8. Remove fuel tank strap retaining bolt. 9. Remove fuel tank-to-front support bracket retaining bolts. 10. Slightly lower fuel tank. Push fuel tank back until lip of tank clears support bracket. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12123 11. Disconnect fuel supply, return and vapor lines from top of fuel tank. See Figure 6. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12124 12. Disconnect fuel pump electrical connector, located in frame rail. See Figure 7. 13. Remove fuel tank from vehicle. 14. Disconnect fuel tank pressure transducer electrical connector. Refer to Figure 8. 15. Clean area around fuel pump to prevent foreign material from entering fuel tank. 16. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel pump during assembly. 17. Remove fuel pump retaining screws, then remove fuel pump. See Figure 8. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12125 18. Disconnect fuel sender electrical connectors. Refer to Figure 9. 19. Remove fuel sender retaining screws, then remove fuel sender. See Figure 9. 20. Install new fuel sender on fuel pump. Tighten screws to 2 Nm (18 lb/in). 21. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 22. Clean fuel pump-to-gas tank mating surface. 23. Install fuel pump. Align marks made during disassembly. Tighten retaining screws to 9-12 Nm (80-107 lb/in). 24. Connect fuel tank pressure transducer electrical connector. 25. Position fuel tank under vehicle. 26. Raise fuel tank enough to connect fuel lines. 27. Connect fuel supply and return lines. 28. Connect fuel pump electrical connector. 29. Position fuel tank in installed position. 30. Install fuel tank-to-front support bracket retaining bolts. Tighten bolts to 34-46 Nm (25-34 lb/ft). 31. Install fuel tank strap retaining bolt. Tighten bolts to 34-46 Nm (25-34 lb/ft). 32. Remove jack. 33. Connect fuel filler and vent hoses to fuel tank. 34. Install skid plate. Torque retaining bolts to 34-46 Nm (25-34 lb/ft). 35. Lower vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12126 36. Fill fuel tank. 37. Connect battery negative cable, then remove memory saver. 38. Start and run engine. 39. Raise vehicle. 40. Inspect fuel system for leaks. 41. Lower vehicle. Mustang 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 4. Remove fuel filler pipe retainers from gas cap side of fuel filler pipe. 5. Raise and support vehicle. 6. Remove screw retaining fuel filler pipe retainer to fuel tank flange.Refer to Figure 10. 7. Remove fuel filler pipe rubber weather boot from inner fender well. See Figure 10. 8. Support fuel tank with adjustable jack. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12127 9. Disconnect fuel pump electrical connector. See Figure 11. 10. Remove fuel tank straps retaining bolts. 11. Slightly lower fuel tank. 12. With an assistant's help, remove filler pipe from fuel tank. The filler pipe is friction fit into the fuel tank, the filler pipe will have to be walked out of the fuel tank. See Figure 12. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12128 13. Disconnect fuel supply, return and vapor lines. See Figure 13. 14. Disconnect fuel sender electrical connector. Refer to Figure 14. 15. Remove fuel tank from vehicle. 16. Clean area around fuel sender to prevent foreign material from entering fuel tank. 17. Place alignment mark across fuel sender and fuel tank. This will assure correct alignment of fuel sender during assembly. 18. Remove fuel sender lock-ring. See Figure 14. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12129 19. Remove and discard fuel sender. 20. Remove and discard fuel sender seal. 21. Lubricate and install new fuel sender seal. 22. Install new fuel sender. Align mark made during disassembly. Tighten lock ring until it contact stops. 23. Connect fuel sender electrical connector. 24. Raise fuel tank enough to connect fuel lines. 25. Connect fuel supply, return and vapor lines. 26. Install fuel filler pipe in fuel tank. 27. Position fuel tank in installed position. 28. Install fuel tank straps. Tighten retaining bolts to 30-40 Nm (22-30 lb/ft). 29. Remove adjustable jack. 30. Connect fuel pump electrical connector. 31. Install fuel filler pipe rubber weather boot to inner fender well. 32. Install screw retaining fuel filler pipe retainer to fuel tank flange. Tighten screw to 7.3-9.0 Nm (65-80 lb/in). 33. Lower vehicle. 34. Install fuel filler pipe retainers to gas cap side of fuel filler pipe. 35. Fill fuel tank. 36. Connect battery negative cable, then remove memory saver. 37. Start and run engine. 38. Raise vehicle. 39. Inspect fuel system for leaks. 40. Lower vehicle. Taurus/Sable 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 4. Raise and support vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12130 5. Disconnect fuel filler and vent hoses from fuel tank. See Figure 15. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12131 6. Disconnect fuel supply and return lines. Refer to Figure 16. 7. Disconnect fuel pump electrical connector. See Figure 16. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12132 8. Disconnect fuel vapor line. See Figure 17. 9. Support fuel tank with adjustable jack. 10. Remove fuel tank strap retaining bolts. 11. Remove fuel tank from vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12133 12. Detach fuel pump wiring harness and fuel lines from fuel tank. Refer to Figure 18. 13. Clean area around fuel pump to prevent foreign material from entering fuel tank. 14. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel pump during assembly. 15. Disconnect fuel pressure transducer electrical connector. See Figure 18. 16. Remove fuel pump lock-ring. 17. Remove fuel pump. 18. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12134 19. Disconnect fuel sender electrical connectors. Refer to Figure 19. 20. Remove fuel sender retaining screw, then remove fuel sender. See Figure 19. 21. Install new fuel sender on fuel pump. Tighten screw to 1 Nm (9 lb/in). 22. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 23. Clean fuel pump-to-gas tank mating surface. 24. Lubricate and install new fuel pump gasket. 25. Install fuel pump. Align marks made during disassembly. Tighten lock ring until it contacts stops. 26. Install fuel pump wiring harness and fuel lines on fuel tank assembly. 27. Connect fuel pressure transducer electrical connector. 28. Install fuel tank in vehicle. Tighten fuel tank straps to 30-40 Nm (22-30 lb/ft). 29. Remove adjustable jack. 30. Connect fuel pump electrical connector. 31. Connect fuel supply, return and vapor lines. 32. Connect fuel filler and vent hoses to fuel tank. 33. Lower vehicle. 34. Fill fuel tank. 35. Connect battery negative cable, then remove memory saver. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12135 36. Start and run engine. 37. Raise vehicle. 38. Inspect fuel system for leaks. 39. Lower vehicle. Windstar 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 4. Raise and support vehicle. 5. Support fuel tank with adjustable jack. 6. Disconnect fuel filler and vent hoses from fuel tank. 7. Disconnect fuel supply, return and vapor lines. See Figure 20. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12136 8. Disconnect fuel pump electrical connector. See Figure 21. 9. Remove fuel tank straps retaining bolts. 10. Remove fuel tank from vehicle. 11. Clean area around fuel pump to prevent foreign material from entering fuel tank. 12. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel during assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12137 13. Detach fuel lines from routing clips and tie strap. See Figure 22. 14. Remove fuel pump lock-ring. 15. Remove fuel pump. 16. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12138 17. Disconnect fuel sender electrical connectors. Refer to Figure 23. 18. Remove fuel sender retaining screw, then remove fuel sender. See Figure 23. 19. Install new fuel sender on fuel pump. Tighten screw to 1 Nm (9 lb/in). 20. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 21. Clean fuel pump-to-gas tank mating surface. 22. Install new fuel pump gasket. 23. Install fuel pump. Align marks made during disassembly. Tighten lock ring until it contact stops. 24. Attach fuel lines to routing clips and install tie strap. Connect fuel lines to fuel pump. Connect electrical connector to pump/sender. 25. Install fuel tank in vehicle. Tighten fuel tank straps to 41-54 Nm (31-39 lb/ft). 26. Connect fuel pump electrical connector. 27. Connect fuel supply, return and vapor lines. 28. Connect fuel filler and vent hoses to fuel tank. 29. Remove adjustable jack. 30. Lower vehicle. 31. Fill fuel tank. 32. Connect battery negative cable, then remove memory saver. 33. Start and run engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12139 34. Raise vehicle. 35. Inspect fuel system for leaks. 36. Lower vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12140 Supplement # 1 - Attachment II LABOR ALLOWANCES Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12141 PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order fuel sender assemblies and the gaskets through normal processing channels. PART NUMBER/DESCRIPTION Fuel Sender Assembly - NOTE: Some of the following applications will require gaskets to be ordered in addition to the sender assemblies. NOTE: Kit Codes "AA" & "BB" are not used. Warning For 1997 Expedition FUEL SENDER REPLACEMENT SUPPLEMENT FOR 1997 EXPEDITION WARNING DO NOT SWALLOW GASOLINE, THESE FUELS ARE HIGHLY TOXIC AND IF SWALLOWED CAN CAUSE DEATH OR PERMANENT INJURY, SWALLOWING METHANOL CAN ALSO CAUSE BLINDNESS. CALL A PHYSICIAN IMMEDIATELY TO TREAT ANYONE WHO HAS SWALLOWED FUEL METHANOL OR FUEL ETHANOL. VOMITING SHOULD BE INDUCED BY OR UNDER THE DIRECTION OF A PHYSICIAN OR POISON CONTROL CENTER. BE AWARE THAT THE ONSET OF POTENTIAL ILL HEALTH EFFECTS MAY BE DELAYED. WARNING AVOID INHALING FUEL VAPORS. INHALING TOO MUCH FUEL VAPOR CAN LEAD TO EYE AND RESPIRATORY TRACT IRRITATION. IN SEVERE CASES, EXCESSIVE OR PROLONGED BREATHING OF FUEL VAPORS CAN CAUSE SERIOUS ILLNESS AND PERMANENT INJURY SUCH AS BLINDNESS. WARNING AVOID GETTING GASOLINE IN YOUR EYES. IF YOU GET ANY FUEL IN YOUR EYES, REMOVE CONTACT LENSES (IF WORN), FLUSH IMMEDIATELY WITH PLENTY OF WATER FOR AT LEAST 15 MINUTES AND SEEK MEDICAL ATTENTION. WARNING IF YOU GET ANY FUEL ON YOUR SKIN, WASH WITH SOAP AND WATER. REPEATED OR PROLONGED SKIN CONTACT WITH FUEL LIQUID OR VAPOR CAUSES SKIN IRRITATION. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12142 WARNING DO NOT OPERATE ENGINE OR SMOKE WHILE REFUELING. Expedition 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Raise and support vehicle. 4. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 5. Disconnect fuel filler and vent hoses from fuel tank. Refer to Figure 1. 6. Disconnect rear EVAP hose from top of fuel tank. See Figure 1. 7. Support fuel tank with adjustable jack. 8. Remove fuel tank straps retaining bolts. The skid plate, fuel tank and straps will be removed as an assembly. 9. Slightly lower fuel tank. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12143 10. Disconnect fuel supply and return lines from top of fuel tank. See Figure 2. 11. Disconnect fuel pump electrical connector, located between the side of the fuel tank and the frame rail. See Figure 3. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12144 12. Slightly lower fuel tank again. 13. Disconnect front EVAP hose from top of fuel tank. 14. Remove fuel tank from vehicle. 15. Clean area around fuel pump to prevent foreign material from entering fuel tank. Refer to Figure 4. 16. Place alignment mark across fuel pump and fuel tank. This will correctly align the fuel pump during reassembly. 17. Remove fuel pump lock-ring, then remove fuel pump. See Figure 4. 18. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12145 19. Disconnect fuel sender electrical connectors. Refer to Figure 5. 20. Remove fuel sender retaining screws, then remove fuel sender. See Figure 5. NOTE: On some vehicles this step may have already been performed. CAUTION Do not cut the main 14 gauge pump ground wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12146 21. Cut a section out of the 18 gauge black grounding wire. See Figure 6. Discard removed black wire. 22. Install new fuel sender on the fuel pump. Tighten screws to 2 Nm (18 lb/in). Note the revised orientation of the float. NOTE: There are two (2) different terminal end types used on the fuel sender ground wire, a box terminal or a ring terminal. These terminal ends are connected to different locations on the fuel sender. 23. Connect fuel sender electrical connectors as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12147 ^ Connect box type terminal end ground wire to location shown in Figure 7. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12148 ^ Connect ring type terminal end ground wire to location shown in Figure 8. ^ Reconnect yellow wire to pump sending unit harness. 24. Clean fuel pump-to-gas tank mating surface. 25. Install new seal onto fuel pump-to-gas tank mating surface. 26. Install fuel pump. Align marks made during disassembly. Tighten lock-ring to 44 Nm (33 lb/ft). 27. Position fuel tank under vehicle. 28. Raise fuel tank enough to connect front EVAP hose. 29. Connect front EVAP hose. 30. Raise fuel tank enough to connect fuel lines. 31. Connect fuel supply and return lines. 32. Connect fuel pump electrical connector. 33. Raise fuel tank to installed position. 34. Install fuel tank strap retaining bolts. Tighten bolts to 46-63 Nm (33-46 lb/ft). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12149 35. Remove jack. 36. Connect rear EVAP hose to top of fuel tank. 37. Connect fuel filler and vent hoses to fuel tank. 38. Refill fuel tank. It may be necessary to refill fuel tank before connecting filler hose. 39. Lower vehicle. 40. Connect battery negative cable, then remove memory saver. 41. Stan and run engine. 42. Raise vehicle. 43. Inspect fuel system for leaks. 44. Lower vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest: > 97-9-16 > Apr > 97 > Fuel Gauge - Erratic and/or Inaccurate Readings Fuel Gauge Sender: Customer Interest Fuel Gauge - Erratic and/or Inaccurate Readings Article No. 97-9-16 04/28/97 GAUGES - FUEL - ERRATIC AND/OR INACCURATE READINGS - VEHICLES BUILT THROUGH 3/97 LIGHT TRUCK: 1997 EXPEDITION ISSUE: The fuel gauge may operate erratically and/or have inaccurate readings. This may be caused by the sensing float being positioned at the extreme aft of the fuel tank. ACTION: Replace the fuel pump and sender assembly with a revised pump and sender. The revised pump and sender has a repositioned sensor assembly to bring the float assembly closer to the center of the fuel tank. This should reduce the possibility of inaccurate and erratic readings. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the fuel tank as outlined in Section 310-01 in the 1997 Expedition Workshop Manual. 2. Remove the fuel pump and sender assembly as outlined in Section 310-01 of the Workshop Manual. NOTE: THERE IS NO NEED TO REMOVE THE SENDING UNIT FROM THE REMOVED PUMP. THE REPLACEMENT PUMP HAS A NEW SENDER FITTED ALREADY. THIS SENDER IS ORIENTED DIFFERENTLY FROM THE REMOVED PART. THIS WILL PUT THE FLOAT CLOSER TO THE CENTER OF THE TANK. 3. Remove the pressure transducer from the removed pump and install it onto the new pump. Make sure the electrical connection is made. 4. Using a new green seal (included with the pump), reinstall the pump and sender into the tank as outlined in Section 310-01 of the Workshop Manual. 5. Reinstall the fuel tank as outlined in Section 310-01 of the Workshop Manual. NOTE: WHEN THE BATTERY IS DISCONNECTED AND RECONNECTED, SOME ABNORMAL DRIVE SYMPTOMS MAY OCCUR WHILE THE VEHICLE RELEARNS ITS ADAPTIVE STRATEGY. THE VEHICLE MAY NEED TO BE DRIVEN 16 km (10 MILES) OR MORE TO RELEARN THE STRATEGY. PART NUMBER PART NAME F75Z-9H307-KC Fuel Pump And Sender Assembly (4X4) F75Z-9H307-LC Fuel Pump And Sender Assembly (4X2 Normal Suspension) F75Z-9H307-MC Fuel Pump And Sender Assembly (4X2 Air Suspension) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 970916A Replace Fuel Pump And 1.5 Hrs. Sender Assembly DEALER CODING CONDITION BASIC PART NO. CODE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest: > 97-9-16 > Apr > 97 > Fuel Gauge - Erratic and/or Inaccurate Readings > Page 12155 9K007 36 OASIS CODES: 204000, 204200 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly Technical Service Bulletin # 97B17 Date: 980201 Campaign - Fuel Gauge/Sender Assembly 97517 OWNER NOTIFICATION PROGRAM Fuel Gauge/Sender Assembly Replacement Original - February, 1998 Dealer Letter Attachment I ^ Administrative Information ^ Refund Codes Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Supplement # 1 - April, 1998 Supplement # 2 - November, 1998 Revised Expiration Date For Owner Notification Program 98B17 - Fuel Gauge/sender Replacement ^ IMPORTANT INFORMATION OWNER NOTIFICATION PROGRAM 97B17 EXPIRATION DATE ^ Attachments not Applicable ^ Customer Notification Letter not Applicable Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12161 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Affected vehicles on the enclosed list. ^ Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12162 Enter claims using DWE. See ACESII Manual, Sections 5 and 6. OWNER REFUNDS See ACESII Manual, Section 3-63 for submission procedures. For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Program Code - 97B17 Misc. Expense - REFUND Misc. Expense - ADMIN. Misc. Expense - 0.2 Hr. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order fuel sender assemblies and the gaskets through normal processing channels. PART NUMBER/DESCRIPTION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12163 Fuel Sender Assembly - NOTE: Some of the following applications will require gaskets to be ordered in addition to the sender assemblies. DEALER PRICE For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. CLAIMS PREPARATION Enter using DWE. Use code information shown below: ^ Program Code - 97B17 ^ Labor Operation Code - See Above See Sections 5 and 6 of the ACESII Manual for detailed instructions Affected Vehicle and Warning Information AFFECTED VEHICLES: CERTAIN 1997 TAURUS/SABLE, EXPLORER/MOUNTAINEER, EXPEDITION, MUSTANG AND 1998 WINDSTAR WARNING DO NOT SWALLOW GASOLINE, THESE FUELS ARE HIGHLY TOXIC AND IF SWALLOWED CAN CAUSE DEATH OR PERMANENT INJURY, SWALLOWING METHANOL CAN ALSO CAUSE BLINDNESS. CALL A PHYSICIAN IMMEDIATELY TO TREAT ANYONE WHO HAS SWALLOWED FUEL METHANOL OR FUEL ETHANOL. VOMITING SHOULD BE INDUCED BY OR UNDER THE DIRECTION OF A PHYSICIAN OR POISON CONTROL CENTER. BE AWARE THAT THE ONSET OF POTENTIAL ILL HEALTH EFFECTS MAY BE DELAYED. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12164 WARNING AVOID INHALING FUEL VAPORS. INHALING TOO MUCH FUEL VAPOR CAN LEAD TO EYE AND RESPIRATORY TRACT IRRITATION. IN SEVERE CASES, EXCESSIVE OR PROLONGED BREATHING OF FUEL VAPORS CAN CAUSE SERIOUS ILLNESS AND PERMANENT INJURY SUCH AS BLINDNESS. WARNING AVOID GETTING GASOLINE IN YOUR EYES. IF YOU GET ANY FUEL IN YOUR EYES, REMOVE CONTRACT LENSES (IF WORN), FLUSH IMMEDIATELY WITH PLENTY OF WATER FOR AT LEAST 15 MINUTES AND SEEK MEDICAL ATTENTION. WARNING IF YOU GET ANY FUEL ON YOUR SKIN, WASH WITH SOAP AND WATER. REPEATED OR PROLONGED SKIN CONTACT WITH FUEL LIQUID OR VAPOR CAUSES SKIN IRRITATION. WARNING DO NOT OPERATE ENGINE OR SMOKE WHILE REFUELING. Expedition 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Raise and support vehicle. 4. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 5. Disconnect fuel filler and vent hoses from fuel tank. Refer to Figure 1. 6. Disconnect rear EVAP hose from top of fuel tank. See Figure 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12165 7. Support fuel tank with adjustable jack. 8. Remove fuel tank straps retaining bolts. The skid plate, fuel tank and straps will be removed as an assembly. 9. Slightly lower fuel tank. 10. Disconnect fuel supply and return lines from top of fuel tank. See Figure 2. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12166 11. Disconnect fuel pump electrical connector, located between the side of the fuel tank and the frame rail. See Figure 3. 12. Slightly lower fuel tank again. 13. Disconnect front EVAP hose from top of fuel tank. 14. Remove fuel tank from vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12167 15. Clean area around fuel pump to prevent foreign material from entering fuel tank. Refer to Figure 4. 16. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel pump during reassembly. 17. Remove fuel pump lock-ring, then remove fuel pump. See Figure 4. 18. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12168 19. Disconnect fuel sender electrical connectors. Refer to Figure 5. 20. Remove fuel sender retaining screws, then remove fuel sender. See Figure 5. 21. Install new fuel sender on fuel pump. Tighten screws to 2 Nm (18 lb/in). 22. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 23. Clean fuel pump-to-gas tank mating surface. 24. Install new seal onto fuel pump-to-gas tank mating surface. 25. Install fuel pump. Align marks made during disassembly. Tighten lock-ring to 44 Nm (33 lb/ft). 26. Position fuel tank under vehicle. 27. Raise fuel tank enough to connect front EVAP hose. 28. Connect front EVAP hose. 29. Raise fuel tank enough to connect fuel lines. 30. Connect fuel supply and return lines. 31. Connect fuel pump electrical connector. 32. Raise fuel tank to installed position. 33. Install fuel tank strap retaining bolts. Tighten bolts to 46-63 Nm (33-46 lb/ft). 34. Remove jack. 35. Connect rear EVAP hose to top of fuel tank. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12169 36. Connect fuel filler and vent hoses to fuel tank. 37. Refill fuel tank. It may be necessary to refill fuel tank before connecting filler hose. 38. Lower vehicle. 39. Connect battery negative cable, then remove memory saver. 40. Stan and run engine. 41. Raise vehicle. 42. Inspect fuel system for leaks. 43. Lower vehicle. Explorer/Mountaineer 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Raise and support vehicle. 4. Remove skid plate retaining bolts, then the skid plate. 5. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 6. Support fuel tank with adjustable jack. 7. Disconnect fuel filler and vent hoses from fuel tank. 8. Remove fuel tank strap retaining bolt. 9. Remove fuel tank-to-front support bracket retaining bolts. 10. Slightly lower fuel tank. Push fuel tank back until lip of tank clears support bracket. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12170 11. Disconnect fuel supply, return and vapor lines from top of fuel tank. See Figure 6. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12171 12. Disconnect fuel pump electrical connector, located in frame rail. See Figure 7. 13. Remove fuel tank from vehicle. 14. Disconnect fuel tank pressure transducer electrical connector. Refer to Figure 8. 15. Clean area around fuel pump to prevent foreign material from entering fuel tank. 16. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel pump during assembly. 17. Remove fuel pump retaining screws, then remove fuel pump. See Figure 8. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12172 18. Disconnect fuel sender electrical connectors. Refer to Figure 9. 19. Remove fuel sender retaining screws, then remove fuel sender. See Figure 9. 20. Install new fuel sender on fuel pump. Tighten screws to 2 Nm (18 lb/in). 21. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 22. Clean fuel pump-to-gas tank mating surface. 23. Install fuel pump. Align marks made during disassembly. Tighten retaining screws to 9-12 Nm (80-107 lb/in). 24. Connect fuel tank pressure transducer electrical connector. 25. Position fuel tank under vehicle. 26. Raise fuel tank enough to connect fuel lines. 27. Connect fuel supply and return lines. 28. Connect fuel pump electrical connector. 29. Position fuel tank in installed position. 30. Install fuel tank-to-front support bracket retaining bolts. Tighten bolts to 34-46 Nm (25-34 lb/ft). 31. Install fuel tank strap retaining bolt. Tighten bolts to 34-46 Nm (25-34 lb/ft). 32. Remove jack. 33. Connect fuel filler and vent hoses to fuel tank. 34. Install skid plate. Torque retaining bolts to 34-46 Nm (25-34 lb/ft). 35. Lower vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12173 36. Fill fuel tank. 37. Connect battery negative cable, then remove memory saver. 38. Start and run engine. 39. Raise vehicle. 40. Inspect fuel system for leaks. 41. Lower vehicle. Mustang 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 4. Remove fuel filler pipe retainers from gas cap side of fuel filler pipe. 5. Raise and support vehicle. 6. Remove screw retaining fuel filler pipe retainer to fuel tank flange.Refer to Figure 10. 7. Remove fuel filler pipe rubber weather boot from inner fender well. See Figure 10. 8. Support fuel tank with adjustable jack. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12174 9. Disconnect fuel pump electrical connector. See Figure 11. 10. Remove fuel tank straps retaining bolts. 11. Slightly lower fuel tank. 12. With an assistant's help, remove filler pipe from fuel tank. The filler pipe is friction fit into the fuel tank, the filler pipe will have to be walked out of the fuel tank. See Figure 12. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12175 13. Disconnect fuel supply, return and vapor lines. See Figure 13. 14. Disconnect fuel sender electrical connector. Refer to Figure 14. 15. Remove fuel tank from vehicle. 16. Clean area around fuel sender to prevent foreign material from entering fuel tank. 17. Place alignment mark across fuel sender and fuel tank. This will assure correct alignment of fuel sender during assembly. 18. Remove fuel sender lock-ring. See Figure 14. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12176 19. Remove and discard fuel sender. 20. Remove and discard fuel sender seal. 21. Lubricate and install new fuel sender seal. 22. Install new fuel sender. Align mark made during disassembly. Tighten lock ring until it contact stops. 23. Connect fuel sender electrical connector. 24. Raise fuel tank enough to connect fuel lines. 25. Connect fuel supply, return and vapor lines. 26. Install fuel filler pipe in fuel tank. 27. Position fuel tank in installed position. 28. Install fuel tank straps. Tighten retaining bolts to 30-40 Nm (22-30 lb/ft). 29. Remove adjustable jack. 30. Connect fuel pump electrical connector. 31. Install fuel filler pipe rubber weather boot to inner fender well. 32. Install screw retaining fuel filler pipe retainer to fuel tank flange. Tighten screw to 7.3-9.0 Nm (65-80 lb/in). 33. Lower vehicle. 34. Install fuel filler pipe retainers to gas cap side of fuel filler pipe. 35. Fill fuel tank. 36. Connect battery negative cable, then remove memory saver. 37. Start and run engine. 38. Raise vehicle. 39. Inspect fuel system for leaks. 40. Lower vehicle. Taurus/Sable 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 4. Raise and support vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12177 5. Disconnect fuel filler and vent hoses from fuel tank. See Figure 15. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12178 6. Disconnect fuel supply and return lines. Refer to Figure 16. 7. Disconnect fuel pump electrical connector. See Figure 16. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12179 8. Disconnect fuel vapor line. See Figure 17. 9. Support fuel tank with adjustable jack. 10. Remove fuel tank strap retaining bolts. 11. Remove fuel tank from vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12180 12. Detach fuel pump wiring harness and fuel lines from fuel tank. Refer to Figure 18. 13. Clean area around fuel pump to prevent foreign material from entering fuel tank. 14. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel pump during assembly. 15. Disconnect fuel pressure transducer electrical connector. See Figure 18. 16. Remove fuel pump lock-ring. 17. Remove fuel pump. 18. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12181 19. Disconnect fuel sender electrical connectors. Refer to Figure 19. 20. Remove fuel sender retaining screw, then remove fuel sender. See Figure 19. 21. Install new fuel sender on fuel pump. Tighten screw to 1 Nm (9 lb/in). 22. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 23. Clean fuel pump-to-gas tank mating surface. 24. Lubricate and install new fuel pump gasket. 25. Install fuel pump. Align marks made during disassembly. Tighten lock ring until it contacts stops. 26. Install fuel pump wiring harness and fuel lines on fuel tank assembly. 27. Connect fuel pressure transducer electrical connector. 28. Install fuel tank in vehicle. Tighten fuel tank straps to 30-40 Nm (22-30 lb/ft). 29. Remove adjustable jack. 30. Connect fuel pump electrical connector. 31. Connect fuel supply, return and vapor lines. 32. Connect fuel filler and vent hoses to fuel tank. 33. Lower vehicle. 34. Fill fuel tank. 35. Connect battery negative cable, then remove memory saver. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12182 36. Start and run engine. 37. Raise vehicle. 38. Inspect fuel system for leaks. 39. Lower vehicle. Windstar 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 4. Raise and support vehicle. 5. Support fuel tank with adjustable jack. 6. Disconnect fuel filler and vent hoses from fuel tank. 7. Disconnect fuel supply, return and vapor lines. See Figure 20. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12183 8. Disconnect fuel pump electrical connector. See Figure 21. 9. Remove fuel tank straps retaining bolts. 10. Remove fuel tank from vehicle. 11. Clean area around fuel pump to prevent foreign material from entering fuel tank. 12. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel during assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12184 13. Detach fuel lines from routing clips and tie strap. See Figure 22. 14. Remove fuel pump lock-ring. 15. Remove fuel pump. 16. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12185 17. Disconnect fuel sender electrical connectors. Refer to Figure 23. 18. Remove fuel sender retaining screw, then remove fuel sender. See Figure 23. 19. Install new fuel sender on fuel pump. Tighten screw to 1 Nm (9 lb/in). 20. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 21. Clean fuel pump-to-gas tank mating surface. 22. Install new fuel pump gasket. 23. Install fuel pump. Align marks made during disassembly. Tighten lock ring until it contact stops. 24. Attach fuel lines to routing clips and install tie strap. Connect fuel lines to fuel pump. Connect electrical connector to pump/sender. 25. Install fuel tank in vehicle. Tighten fuel tank straps to 41-54 Nm (31-39 lb/ft). 26. Connect fuel pump electrical connector. 27. Connect fuel supply, return and vapor lines. 28. Connect fuel filler and vent hoses to fuel tank. 29. Remove adjustable jack. 30. Lower vehicle. 31. Fill fuel tank. 32. Connect battery negative cable, then remove memory saver. 33. Start and run engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12186 34. Raise vehicle. 35. Inspect fuel system for leaks. 36. Lower vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12187 Supplement # 1 - Attachment II LABOR ALLOWANCES Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12188 PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order fuel sender assemblies and the gaskets through normal processing channels. PART NUMBER/DESCRIPTION Fuel Sender Assembly - NOTE: Some of the following applications will require gaskets to be ordered in addition to the sender assemblies. NOTE: Kit Codes "AA" & "BB" are not used. Warning For 1997 Expedition FUEL SENDER REPLACEMENT SUPPLEMENT FOR 1997 EXPEDITION WARNING DO NOT SWALLOW GASOLINE, THESE FUELS ARE HIGHLY TOXIC AND IF SWALLOWED CAN CAUSE DEATH OR PERMANENT INJURY, SWALLOWING METHANOL CAN ALSO CAUSE BLINDNESS. CALL A PHYSICIAN IMMEDIATELY TO TREAT ANYONE WHO HAS SWALLOWED FUEL METHANOL OR FUEL ETHANOL. VOMITING SHOULD BE INDUCED BY OR UNDER THE DIRECTION OF A PHYSICIAN OR POISON CONTROL CENTER. BE AWARE THAT THE ONSET OF POTENTIAL ILL HEALTH EFFECTS MAY BE DELAYED. WARNING AVOID INHALING FUEL VAPORS. INHALING TOO MUCH FUEL VAPOR CAN LEAD TO EYE AND RESPIRATORY TRACT IRRITATION. IN SEVERE CASES, EXCESSIVE OR PROLONGED BREATHING OF FUEL VAPORS CAN CAUSE SERIOUS ILLNESS AND PERMANENT INJURY SUCH AS BLINDNESS. WARNING AVOID GETTING GASOLINE IN YOUR EYES. IF YOU GET ANY FUEL IN YOUR EYES, REMOVE CONTACT LENSES (IF WORN), FLUSH IMMEDIATELY WITH PLENTY OF WATER FOR AT LEAST 15 MINUTES AND SEEK MEDICAL ATTENTION. WARNING IF YOU GET ANY FUEL ON YOUR SKIN, WASH WITH SOAP AND WATER. REPEATED OR PROLONGED SKIN CONTACT WITH FUEL LIQUID OR VAPOR CAUSES SKIN IRRITATION. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12189 WARNING DO NOT OPERATE ENGINE OR SMOKE WHILE REFUELING. Expedition 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Raise and support vehicle. 4. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 5. Disconnect fuel filler and vent hoses from fuel tank. Refer to Figure 1. 6. Disconnect rear EVAP hose from top of fuel tank. See Figure 1. 7. Support fuel tank with adjustable jack. 8. Remove fuel tank straps retaining bolts. The skid plate, fuel tank and straps will be removed as an assembly. 9. Slightly lower fuel tank. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12190 10. Disconnect fuel supply and return lines from top of fuel tank. See Figure 2. 11. Disconnect fuel pump electrical connector, located between the side of the fuel tank and the frame rail. See Figure 3. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12191 12. Slightly lower fuel tank again. 13. Disconnect front EVAP hose from top of fuel tank. 14. Remove fuel tank from vehicle. 15. Clean area around fuel pump to prevent foreign material from entering fuel tank. Refer to Figure 4. 16. Place alignment mark across fuel pump and fuel tank. This will correctly align the fuel pump during reassembly. 17. Remove fuel pump lock-ring, then remove fuel pump. See Figure 4. 18. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12192 19. Disconnect fuel sender electrical connectors. Refer to Figure 5. 20. Remove fuel sender retaining screws, then remove fuel sender. See Figure 5. NOTE: On some vehicles this step may have already been performed. CAUTION Do not cut the main 14 gauge pump ground wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12193 21. Cut a section out of the 18 gauge black grounding wire. See Figure 6. Discard removed black wire. 22. Install new fuel sender on the fuel pump. Tighten screws to 2 Nm (18 lb/in). Note the revised orientation of the float. NOTE: There are two (2) different terminal end types used on the fuel sender ground wire, a box terminal or a ring terminal. These terminal ends are connected to different locations on the fuel sender. 23. Connect fuel sender electrical connectors as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12194 ^ Connect box type terminal end ground wire to location shown in Figure 7. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12195 ^ Connect ring type terminal end ground wire to location shown in Figure 8. ^ Reconnect yellow wire to pump sending unit harness. 24. Clean fuel pump-to-gas tank mating surface. 25. Install new seal onto fuel pump-to-gas tank mating surface. 26. Install fuel pump. Align marks made during disassembly. Tighten lock-ring to 44 Nm (33 lb/ft). 27. Position fuel tank under vehicle. 28. Raise fuel tank enough to connect front EVAP hose. 29. Connect front EVAP hose. 30. Raise fuel tank enough to connect fuel lines. 31. Connect fuel supply and return lines. 32. Connect fuel pump electrical connector. 33. Raise fuel tank to installed position. 34. Install fuel tank strap retaining bolts. Tighten bolts to 46-63 Nm (33-46 lb/ft). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12196 35. Remove jack. 36. Connect rear EVAP hose to top of fuel tank. 37. Connect fuel filler and vent hoses to fuel tank. 38. Refill fuel tank. It may be necessary to refill fuel tank before connecting filler hose. 39. Lower vehicle. 40. Connect battery negative cable, then remove memory saver. 41. Stan and run engine. 42. Raise vehicle. 43. Inspect fuel system for leaks. 44. Lower vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97-9-16 > Apr > 97 > Fuel Gauge - Erratic and/or Inaccurate Readings Fuel Gauge Sender: All Technical Service Bulletins Fuel Gauge - Erratic and/or Inaccurate Readings Article No. 97-9-16 04/28/97 GAUGES - FUEL - ERRATIC AND/OR INACCURATE READINGS - VEHICLES BUILT THROUGH 3/97 LIGHT TRUCK: 1997 EXPEDITION ISSUE: The fuel gauge may operate erratically and/or have inaccurate readings. This may be caused by the sensing float being positioned at the extreme aft of the fuel tank. ACTION: Replace the fuel pump and sender assembly with a revised pump and sender. The revised pump and sender has a repositioned sensor assembly to bring the float assembly closer to the center of the fuel tank. This should reduce the possibility of inaccurate and erratic readings. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the fuel tank as outlined in Section 310-01 in the 1997 Expedition Workshop Manual. 2. Remove the fuel pump and sender assembly as outlined in Section 310-01 of the Workshop Manual. NOTE: THERE IS NO NEED TO REMOVE THE SENDING UNIT FROM THE REMOVED PUMP. THE REPLACEMENT PUMP HAS A NEW SENDER FITTED ALREADY. THIS SENDER IS ORIENTED DIFFERENTLY FROM THE REMOVED PART. THIS WILL PUT THE FLOAT CLOSER TO THE CENTER OF THE TANK. 3. Remove the pressure transducer from the removed pump and install it onto the new pump. Make sure the electrical connection is made. 4. Using a new green seal (included with the pump), reinstall the pump and sender into the tank as outlined in Section 310-01 of the Workshop Manual. 5. Reinstall the fuel tank as outlined in Section 310-01 of the Workshop Manual. NOTE: WHEN THE BATTERY IS DISCONNECTED AND RECONNECTED, SOME ABNORMAL DRIVE SYMPTOMS MAY OCCUR WHILE THE VEHICLE RELEARNS ITS ADAPTIVE STRATEGY. THE VEHICLE MAY NEED TO BE DRIVEN 16 km (10 MILES) OR MORE TO RELEARN THE STRATEGY. PART NUMBER PART NAME F75Z-9H307-KC Fuel Pump And Sender Assembly (4X4) F75Z-9H307-LC Fuel Pump And Sender Assembly (4X2 Normal Suspension) F75Z-9H307-MC Fuel Pump And Sender Assembly (4X2 Air Suspension) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 970916A Replace Fuel Pump And 1.5 Hrs. Sender Assembly DEALER CODING CONDITION BASIC PART NO. CODE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 97-9-16 > Apr > 97 > Fuel Gauge - Erratic and/or Inaccurate Readings > Page 12201 9K007 36 OASIS CODES: 204000, 204200 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97-25-8 > Dec > 97 > Engine - Rough Running/MIL ON/DTC'S Set Fuel Gauge Sender: All Technical Service Bulletins Fuel Gauge - Erratic and/or Inaccurate Readings Article No. 97-9-16 04/28/97 GAUGES - FUEL - ERRATIC AND/OR INACCURATE READINGS - VEHICLES BUILT THROUGH 3/97 LIGHT TRUCK: 1997 EXPEDITION ISSUE: The fuel gauge may operate erratically and/or have inaccurate readings. This may be caused by the sensing float being positioned at the extreme aft of the fuel tank. ACTION: Replace the fuel pump and sender assembly with a revised pump and sender. The revised pump and sender has a repositioned sensor assembly to bring the float assembly closer to the center of the fuel tank. This should reduce the possibility of inaccurate and erratic readings. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the fuel tank as outlined in Section 310-01 in the 1997 Expedition Workshop Manual. 2. Remove the fuel pump and sender assembly as outlined in Section 310-01 of the Workshop Manual. NOTE: THERE IS NO NEED TO REMOVE THE SENDING UNIT FROM THE REMOVED PUMP. THE REPLACEMENT PUMP HAS A NEW SENDER FITTED ALREADY. THIS SENDER IS ORIENTED DIFFERENTLY FROM THE REMOVED PART. THIS WILL PUT THE FLOAT CLOSER TO THE CENTER OF THE TANK. 3. Remove the pressure transducer from the removed pump and install it onto the new pump. Make sure the electrical connection is made. 4. Using a new green seal (included with the pump), reinstall the pump and sender into the tank as outlined in Section 310-01 of the Workshop Manual. 5. Reinstall the fuel tank as outlined in Section 310-01 of the Workshop Manual. NOTE: WHEN THE BATTERY IS DISCONNECTED AND RECONNECTED, SOME ABNORMAL DRIVE SYMPTOMS MAY OCCUR WHILE THE VEHICLE RELEARNS ITS ADAPTIVE STRATEGY. THE VEHICLE MAY NEED TO BE DRIVEN 16 km (10 MILES) OR MORE TO RELEARN THE STRATEGY. PART NUMBER PART NAME F75Z-9H307-KC Fuel Pump And Sender Assembly (4X4) F75Z-9H307-LC Fuel Pump And Sender Assembly (4X2 Normal Suspension) F75Z-9H307-MC Fuel Pump And Sender Assembly (4X2 Air Suspension) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 970916A Replace Fuel Pump And 1.5 Hrs. Sender Assembly DEALER CODING CONDITION BASIC PART NO. CODE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97-25-8 > Dec > 97 > Engine - Rough Running/MIL ON/DTC'S Set > Page 12207 9K007 36 OASIS CODES: 204000, 204200 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly Technical Service Bulletin # 97B17 Date: 980201 Campaign - Fuel Gauge/Sender Assembly 97517 OWNER NOTIFICATION PROGRAM Fuel Gauge/Sender Assembly Replacement Original - February, 1998 Dealer Letter Attachment I ^ Administrative Information ^ Refund Codes Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Supplement # 1 - April, 1998 Supplement # 2 - November, 1998 Revised Expiration Date For Owner Notification Program 98B17 - Fuel Gauge/sender Replacement ^ IMPORTANT INFORMATION OWNER NOTIFICATION PROGRAM 97B17 EXPIRATION DATE ^ Attachments not Applicable ^ Customer Notification Letter not Applicable Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12213 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Affected vehicles on the enclosed list. ^ Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12214 Enter claims using DWE. See ACESII Manual, Sections 5 and 6. OWNER REFUNDS See ACESII Manual, Section 3-63 for submission procedures. For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Program Code - 97B17 Misc. Expense - REFUND Misc. Expense - ADMIN. Misc. Expense - 0.2 Hr. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order fuel sender assemblies and the gaskets through normal processing channels. PART NUMBER/DESCRIPTION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12215 Fuel Sender Assembly - NOTE: Some of the following applications will require gaskets to be ordered in addition to the sender assemblies. DEALER PRICE For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. CLAIMS PREPARATION Enter using DWE. Use code information shown below: ^ Program Code - 97B17 ^ Labor Operation Code - See Above See Sections 5 and 6 of the ACESII Manual for detailed instructions Affected Vehicle and Warning Information AFFECTED VEHICLES: CERTAIN 1997 TAURUS/SABLE, EXPLORER/MOUNTAINEER, EXPEDITION, MUSTANG AND 1998 WINDSTAR WARNING DO NOT SWALLOW GASOLINE, THESE FUELS ARE HIGHLY TOXIC AND IF SWALLOWED CAN CAUSE DEATH OR PERMANENT INJURY, SWALLOWING METHANOL CAN ALSO CAUSE BLINDNESS. CALL A PHYSICIAN IMMEDIATELY TO TREAT ANYONE WHO HAS SWALLOWED FUEL METHANOL OR FUEL ETHANOL. VOMITING SHOULD BE INDUCED BY OR UNDER THE DIRECTION OF A PHYSICIAN OR POISON CONTROL CENTER. BE AWARE THAT THE ONSET OF POTENTIAL ILL HEALTH EFFECTS MAY BE DELAYED. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12216 WARNING AVOID INHALING FUEL VAPORS. INHALING TOO MUCH FUEL VAPOR CAN LEAD TO EYE AND RESPIRATORY TRACT IRRITATION. IN SEVERE CASES, EXCESSIVE OR PROLONGED BREATHING OF FUEL VAPORS CAN CAUSE SERIOUS ILLNESS AND PERMANENT INJURY SUCH AS BLINDNESS. WARNING AVOID GETTING GASOLINE IN YOUR EYES. IF YOU GET ANY FUEL IN YOUR EYES, REMOVE CONTRACT LENSES (IF WORN), FLUSH IMMEDIATELY WITH PLENTY OF WATER FOR AT LEAST 15 MINUTES AND SEEK MEDICAL ATTENTION. WARNING IF YOU GET ANY FUEL ON YOUR SKIN, WASH WITH SOAP AND WATER. REPEATED OR PROLONGED SKIN CONTACT WITH FUEL LIQUID OR VAPOR CAUSES SKIN IRRITATION. WARNING DO NOT OPERATE ENGINE OR SMOKE WHILE REFUELING. Expedition 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Raise and support vehicle. 4. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 5. Disconnect fuel filler and vent hoses from fuel tank. Refer to Figure 1. 6. Disconnect rear EVAP hose from top of fuel tank. See Figure 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12217 7. Support fuel tank with adjustable jack. 8. Remove fuel tank straps retaining bolts. The skid plate, fuel tank and straps will be removed as an assembly. 9. Slightly lower fuel tank. 10. Disconnect fuel supply and return lines from top of fuel tank. See Figure 2. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12218 11. Disconnect fuel pump electrical connector, located between the side of the fuel tank and the frame rail. See Figure 3. 12. Slightly lower fuel tank again. 13. Disconnect front EVAP hose from top of fuel tank. 14. Remove fuel tank from vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12219 15. Clean area around fuel pump to prevent foreign material from entering fuel tank. Refer to Figure 4. 16. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel pump during reassembly. 17. Remove fuel pump lock-ring, then remove fuel pump. See Figure 4. 18. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12220 19. Disconnect fuel sender electrical connectors. Refer to Figure 5. 20. Remove fuel sender retaining screws, then remove fuel sender. See Figure 5. 21. Install new fuel sender on fuel pump. Tighten screws to 2 Nm (18 lb/in). 22. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 23. Clean fuel pump-to-gas tank mating surface. 24. Install new seal onto fuel pump-to-gas tank mating surface. 25. Install fuel pump. Align marks made during disassembly. Tighten lock-ring to 44 Nm (33 lb/ft). 26. Position fuel tank under vehicle. 27. Raise fuel tank enough to connect front EVAP hose. 28. Connect front EVAP hose. 29. Raise fuel tank enough to connect fuel lines. 30. Connect fuel supply and return lines. 31. Connect fuel pump electrical connector. 32. Raise fuel tank to installed position. 33. Install fuel tank strap retaining bolts. Tighten bolts to 46-63 Nm (33-46 lb/ft). 34. Remove jack. 35. Connect rear EVAP hose to top of fuel tank. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12221 36. Connect fuel filler and vent hoses to fuel tank. 37. Refill fuel tank. It may be necessary to refill fuel tank before connecting filler hose. 38. Lower vehicle. 39. Connect battery negative cable, then remove memory saver. 40. Stan and run engine. 41. Raise vehicle. 42. Inspect fuel system for leaks. 43. Lower vehicle. Explorer/Mountaineer 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Raise and support vehicle. 4. Remove skid plate retaining bolts, then the skid plate. 5. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 6. Support fuel tank with adjustable jack. 7. Disconnect fuel filler and vent hoses from fuel tank. 8. Remove fuel tank strap retaining bolt. 9. Remove fuel tank-to-front support bracket retaining bolts. 10. Slightly lower fuel tank. Push fuel tank back until lip of tank clears support bracket. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12222 11. Disconnect fuel supply, return and vapor lines from top of fuel tank. See Figure 6. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12223 12. Disconnect fuel pump electrical connector, located in frame rail. See Figure 7. 13. Remove fuel tank from vehicle. 14. Disconnect fuel tank pressure transducer electrical connector. Refer to Figure 8. 15. Clean area around fuel pump to prevent foreign material from entering fuel tank. 16. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel pump during assembly. 17. Remove fuel pump retaining screws, then remove fuel pump. See Figure 8. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12224 18. Disconnect fuel sender electrical connectors. Refer to Figure 9. 19. Remove fuel sender retaining screws, then remove fuel sender. See Figure 9. 20. Install new fuel sender on fuel pump. Tighten screws to 2 Nm (18 lb/in). 21. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 22. Clean fuel pump-to-gas tank mating surface. 23. Install fuel pump. Align marks made during disassembly. Tighten retaining screws to 9-12 Nm (80-107 lb/in). 24. Connect fuel tank pressure transducer electrical connector. 25. Position fuel tank under vehicle. 26. Raise fuel tank enough to connect fuel lines. 27. Connect fuel supply and return lines. 28. Connect fuel pump electrical connector. 29. Position fuel tank in installed position. 30. Install fuel tank-to-front support bracket retaining bolts. Tighten bolts to 34-46 Nm (25-34 lb/ft). 31. Install fuel tank strap retaining bolt. Tighten bolts to 34-46 Nm (25-34 lb/ft). 32. Remove jack. 33. Connect fuel filler and vent hoses to fuel tank. 34. Install skid plate. Torque retaining bolts to 34-46 Nm (25-34 lb/ft). 35. Lower vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12225 36. Fill fuel tank. 37. Connect battery negative cable, then remove memory saver. 38. Start and run engine. 39. Raise vehicle. 40. Inspect fuel system for leaks. 41. Lower vehicle. Mustang 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 4. Remove fuel filler pipe retainers from gas cap side of fuel filler pipe. 5. Raise and support vehicle. 6. Remove screw retaining fuel filler pipe retainer to fuel tank flange.Refer to Figure 10. 7. Remove fuel filler pipe rubber weather boot from inner fender well. See Figure 10. 8. Support fuel tank with adjustable jack. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12226 9. Disconnect fuel pump electrical connector. See Figure 11. 10. Remove fuel tank straps retaining bolts. 11. Slightly lower fuel tank. 12. With an assistant's help, remove filler pipe from fuel tank. The filler pipe is friction fit into the fuel tank, the filler pipe will have to be walked out of the fuel tank. See Figure 12. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12227 13. Disconnect fuel supply, return and vapor lines. See Figure 13. 14. Disconnect fuel sender electrical connector. Refer to Figure 14. 15. Remove fuel tank from vehicle. 16. Clean area around fuel sender to prevent foreign material from entering fuel tank. 17. Place alignment mark across fuel sender and fuel tank. This will assure correct alignment of fuel sender during assembly. 18. Remove fuel sender lock-ring. See Figure 14. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12228 19. Remove and discard fuel sender. 20. Remove and discard fuel sender seal. 21. Lubricate and install new fuel sender seal. 22. Install new fuel sender. Align mark made during disassembly. Tighten lock ring until it contact stops. 23. Connect fuel sender electrical connector. 24. Raise fuel tank enough to connect fuel lines. 25. Connect fuel supply, return and vapor lines. 26. Install fuel filler pipe in fuel tank. 27. Position fuel tank in installed position. 28. Install fuel tank straps. Tighten retaining bolts to 30-40 Nm (22-30 lb/ft). 29. Remove adjustable jack. 30. Connect fuel pump electrical connector. 31. Install fuel filler pipe rubber weather boot to inner fender well. 32. Install screw retaining fuel filler pipe retainer to fuel tank flange. Tighten screw to 7.3-9.0 Nm (65-80 lb/in). 33. Lower vehicle. 34. Install fuel filler pipe retainers to gas cap side of fuel filler pipe. 35. Fill fuel tank. 36. Connect battery negative cable, then remove memory saver. 37. Start and run engine. 38. Raise vehicle. 39. Inspect fuel system for leaks. 40. Lower vehicle. Taurus/Sable 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 4. Raise and support vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12229 5. Disconnect fuel filler and vent hoses from fuel tank. See Figure 15. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12230 6. Disconnect fuel supply and return lines. Refer to Figure 16. 7. Disconnect fuel pump electrical connector. See Figure 16. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12231 8. Disconnect fuel vapor line. See Figure 17. 9. Support fuel tank with adjustable jack. 10. Remove fuel tank strap retaining bolts. 11. Remove fuel tank from vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12232 12. Detach fuel pump wiring harness and fuel lines from fuel tank. Refer to Figure 18. 13. Clean area around fuel pump to prevent foreign material from entering fuel tank. 14. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel pump during assembly. 15. Disconnect fuel pressure transducer electrical connector. See Figure 18. 16. Remove fuel pump lock-ring. 17. Remove fuel pump. 18. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12233 19. Disconnect fuel sender electrical connectors. Refer to Figure 19. 20. Remove fuel sender retaining screw, then remove fuel sender. See Figure 19. 21. Install new fuel sender on fuel pump. Tighten screw to 1 Nm (9 lb/in). 22. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 23. Clean fuel pump-to-gas tank mating surface. 24. Lubricate and install new fuel pump gasket. 25. Install fuel pump. Align marks made during disassembly. Tighten lock ring until it contacts stops. 26. Install fuel pump wiring harness and fuel lines on fuel tank assembly. 27. Connect fuel pressure transducer electrical connector. 28. Install fuel tank in vehicle. Tighten fuel tank straps to 30-40 Nm (22-30 lb/ft). 29. Remove adjustable jack. 30. Connect fuel pump electrical connector. 31. Connect fuel supply, return and vapor lines. 32. Connect fuel filler and vent hoses to fuel tank. 33. Lower vehicle. 34. Fill fuel tank. 35. Connect battery negative cable, then remove memory saver. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12234 36. Start and run engine. 37. Raise vehicle. 38. Inspect fuel system for leaks. 39. Lower vehicle. Windstar 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 4. Raise and support vehicle. 5. Support fuel tank with adjustable jack. 6. Disconnect fuel filler and vent hoses from fuel tank. 7. Disconnect fuel supply, return and vapor lines. See Figure 20. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12235 8. Disconnect fuel pump electrical connector. See Figure 21. 9. Remove fuel tank straps retaining bolts. 10. Remove fuel tank from vehicle. 11. Clean area around fuel pump to prevent foreign material from entering fuel tank. 12. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel during assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12236 13. Detach fuel lines from routing clips and tie strap. See Figure 22. 14. Remove fuel pump lock-ring. 15. Remove fuel pump. 16. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12237 17. Disconnect fuel sender electrical connectors. Refer to Figure 23. 18. Remove fuel sender retaining screw, then remove fuel sender. See Figure 23. 19. Install new fuel sender on fuel pump. Tighten screw to 1 Nm (9 lb/in). 20. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 21. Clean fuel pump-to-gas tank mating surface. 22. Install new fuel pump gasket. 23. Install fuel pump. Align marks made during disassembly. Tighten lock ring until it contact stops. 24. Attach fuel lines to routing clips and install tie strap. Connect fuel lines to fuel pump. Connect electrical connector to pump/sender. 25. Install fuel tank in vehicle. Tighten fuel tank straps to 41-54 Nm (31-39 lb/ft). 26. Connect fuel pump electrical connector. 27. Connect fuel supply, return and vapor lines. 28. Connect fuel filler and vent hoses to fuel tank. 29. Remove adjustable jack. 30. Lower vehicle. 31. Fill fuel tank. 32. Connect battery negative cable, then remove memory saver. 33. Start and run engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12238 34. Raise vehicle. 35. Inspect fuel system for leaks. 36. Lower vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12239 Supplement # 1 - Attachment II LABOR ALLOWANCES Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12240 PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order fuel sender assemblies and the gaskets through normal processing channels. PART NUMBER/DESCRIPTION Fuel Sender Assembly - NOTE: Some of the following applications will require gaskets to be ordered in addition to the sender assemblies. NOTE: Kit Codes "AA" & "BB" are not used. Warning For 1997 Expedition FUEL SENDER REPLACEMENT SUPPLEMENT FOR 1997 EXPEDITION WARNING DO NOT SWALLOW GASOLINE, THESE FUELS ARE HIGHLY TOXIC AND IF SWALLOWED CAN CAUSE DEATH OR PERMANENT INJURY, SWALLOWING METHANOL CAN ALSO CAUSE BLINDNESS. CALL A PHYSICIAN IMMEDIATELY TO TREAT ANYONE WHO HAS SWALLOWED FUEL METHANOL OR FUEL ETHANOL. VOMITING SHOULD BE INDUCED BY OR UNDER THE DIRECTION OF A PHYSICIAN OR POISON CONTROL CENTER. BE AWARE THAT THE ONSET OF POTENTIAL ILL HEALTH EFFECTS MAY BE DELAYED. WARNING AVOID INHALING FUEL VAPORS. INHALING TOO MUCH FUEL VAPOR CAN LEAD TO EYE AND RESPIRATORY TRACT IRRITATION. IN SEVERE CASES, EXCESSIVE OR PROLONGED BREATHING OF FUEL VAPORS CAN CAUSE SERIOUS ILLNESS AND PERMANENT INJURY SUCH AS BLINDNESS. WARNING AVOID GETTING GASOLINE IN YOUR EYES. IF YOU GET ANY FUEL IN YOUR EYES, REMOVE CONTACT LENSES (IF WORN), FLUSH IMMEDIATELY WITH PLENTY OF WATER FOR AT LEAST 15 MINUTES AND SEEK MEDICAL ATTENTION. WARNING IF YOU GET ANY FUEL ON YOUR SKIN, WASH WITH SOAP AND WATER. REPEATED OR PROLONGED SKIN CONTACT WITH FUEL LIQUID OR VAPOR CAUSES SKIN IRRITATION. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12241 WARNING DO NOT OPERATE ENGINE OR SMOKE WHILE REFUELING. Expedition 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Raise and support vehicle. 4. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 5. Disconnect fuel filler and vent hoses from fuel tank. Refer to Figure 1. 6. Disconnect rear EVAP hose from top of fuel tank. See Figure 1. 7. Support fuel tank with adjustable jack. 8. Remove fuel tank straps retaining bolts. The skid plate, fuel tank and straps will be removed as an assembly. 9. Slightly lower fuel tank. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12242 10. Disconnect fuel supply and return lines from top of fuel tank. See Figure 2. 11. Disconnect fuel pump electrical connector, located between the side of the fuel tank and the frame rail. See Figure 3. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12243 12. Slightly lower fuel tank again. 13. Disconnect front EVAP hose from top of fuel tank. 14. Remove fuel tank from vehicle. 15. Clean area around fuel pump to prevent foreign material from entering fuel tank. Refer to Figure 4. 16. Place alignment mark across fuel pump and fuel tank. This will correctly align the fuel pump during reassembly. 17. Remove fuel pump lock-ring, then remove fuel pump. See Figure 4. 18. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12244 19. Disconnect fuel sender electrical connectors. Refer to Figure 5. 20. Remove fuel sender retaining screws, then remove fuel sender. See Figure 5. NOTE: On some vehicles this step may have already been performed. CAUTION Do not cut the main 14 gauge pump ground wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12245 21. Cut a section out of the 18 gauge black grounding wire. See Figure 6. Discard removed black wire. 22. Install new fuel sender on the fuel pump. Tighten screws to 2 Nm (18 lb/in). Note the revised orientation of the float. NOTE: There are two (2) different terminal end types used on the fuel sender ground wire, a box terminal or a ring terminal. These terminal ends are connected to different locations on the fuel sender. 23. Connect fuel sender electrical connectors as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12246 ^ Connect box type terminal end ground wire to location shown in Figure 7. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12247 ^ Connect ring type terminal end ground wire to location shown in Figure 8. ^ Reconnect yellow wire to pump sending unit harness. 24. Clean fuel pump-to-gas tank mating surface. 25. Install new seal onto fuel pump-to-gas tank mating surface. 26. Install fuel pump. Align marks made during disassembly. Tighten lock-ring to 44 Nm (33 lb/ft). 27. Position fuel tank under vehicle. 28. Raise fuel tank enough to connect front EVAP hose. 29. Connect front EVAP hose. 30. Raise fuel tank enough to connect fuel lines. 31. Connect fuel supply and return lines. 32. Connect fuel pump electrical connector. 33. Raise fuel tank to installed position. 34. Install fuel tank strap retaining bolts. Tighten bolts to 46-63 Nm (33-46 lb/ft). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12248 35. Remove jack. 36. Connect rear EVAP hose to top of fuel tank. 37. Connect fuel filler and vent hoses to fuel tank. 38. Refill fuel tank. It may be necessary to refill fuel tank before connecting filler hose. 39. Lower vehicle. 40. Connect battery negative cable, then remove memory saver. 41. Stan and run engine. 42. Raise vehicle. 43. Inspect fuel system for leaks. 44. Lower vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming Deactivation Procedure 1. Disconnect positive battery cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Wait one minute. This is the time required for backup power supply in air bag diagnostic monitor to deplete its stored energy. 3. Remove two back cover plugs and remove screw and washer assemblies retaining driver side air bag module to steering wheel. Disconnect horn electrical connector. Disconnect driver air bag sliding contact electrical connector. Remove driver side air bag module from vehicle. WARNING: Place air bag module on bench with trim cover facing up. 4. Connect Rotunda Air Bag Simulator 105-R0011 or equivalent to vehicle harness at top of steering column. 5. Remove passenger side air bag module. Install Rotunda Air Bag Simulator 105-00012 or equivalent on vehicle harness connector in place of passenger side air bag module. 6. Reconnect positive battery cable. Reactivation Procedure 1. Disconnect positive battery cable. WARNING: The air bag simulator must be removed and the air bag reconnected when the system is reactivated. 2. Wait one minute for backup power supply in air bag diagnostic monitor to deplete stored energy. 3. Remove air bag simulator from vehicle harness connector at top of steering column. 4. Reconnect driver side air bag module. 5. Position driver side air bag module on steering wheel and secure with two screw and washer assemblies (8 mm). Tighten screw and washer assemblies to 10-13 Nm (89-115 lb in). Install two back cover plugs. 6. Remove air bag simulator from vehicle harness connector on passenger side. Reconnect and install passenger side air bag module. 7. Reconnect positive battery cable. 8. Prove out system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 12254 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The check list below should be completed following diagnosis or service of any air bag system concern: 1. Are both air bag crash sensors connected and mounted to the vehicle? 2. Is 3-way connector at base of steering column connected? 3. Are the air bags or air bag simulators connected? 4. Is air bag diagnostic monitor connected? 5. Is vehicle battery connected? Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Service and Repair Key Reminder Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key and turn to the RUN position. 2. Press the (A) ignition switch lock cylinder release tab while pulling out the (B) ignition switch lock cylinder. 3. Remove the key in ignition warning switch. 1. Pry clip down. 2. Push key in ignition warning switch off the rear of the ignition switch lock cylinder. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Service and Repair > Page 12258 2. Verify ignition switch lock cylinder operation. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Testing and Inspection Low Fuel Lamp/Indicator: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection Malfunction Indicator Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Testing and Inspection Odometer: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair NOTE : The RESET procedure is found ONLY in the Owners Manual. For most Ford vehicles, the RESET procedure mainly includes just pressing the RESET button for five(5) seconds but it is recommended that the Owners Manual is consulted first. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Testing and Inspection Oil Pressure Gauge: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation The transmission control switch (TCS) is a momentary contact switch. When the switch is pressed, a signal is sent to the powertrain control module (PCM) to allow automatic shifts from first through fourth gears or first through third gears only. The PCM energizes the transmission control indicator lamp (TCIL) when the switch has been pressed to cancel overdrive. The TCIL indicates overdrive cancel mode activated (lamp on) and electronic pressure control (EPC) circuit shorted (lamp flashing) or monitored sensor failure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Overdrive Indicator Lamp > Component Information > Description and Operation > Page 12277 Overdrive Indicator Lamp: Testing and Inspection The TCIL indicates overdrive cancel mode activated (lamp on), electronic pressure control circuit shorted or monitored sensor failure (lamp flashing). For testing procedures, Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Testing and Inspection Speedometer Module: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation The GEM controls the Driver safety belt not fastened warning lamp. The safety belt warning lamp warns that the safety belt is not fastened. The safety belt warning lamp illuminates when it is grounded and turns OFF when the circuit is open. The safety belt warning lamp will be illuminated when: - Safety belt is not fastened and the ignition switch is turned from the OFF/LOCK or ACC to the RUN or START position. The safety belt warning lamp will turn off when: - Safety belt fastened. - Ignition switch is switched from the RUN or START to the OFF/LOCK or ACC position. - After lamp is illuminated for 61 seconds. The safety belt warning lamp inputs are: - Ignition switch START position (battery potential when in START). - Ignition switch RUN position (battery potential on both RUN and RUN/ACC inputs). - Driver safety belt switch (grounded when not fastened, open circuit when fastened). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Description and Operation > Page 12285 Seat Belt Reminder Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Description and Operation Dimmer Switch: Description and Operation The panel dimmer switch is integrated into the headlamp switch and controls the interior lamps by activating the interior lamp relay. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Directional Sensor > Component Information > Locations Directional Sensor: Locations Body View The Compass Sensor is located in the overhead console. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Directional Sensor > Component Information > Locations > Page 12293 Compass Sensor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign Fuel Gauge/Sender Assembly Technical Service Bulletin # 97B17 Date: 980201 Campaign - Fuel Gauge/Sender Assembly 97517 OWNER NOTIFICATION PROGRAM Fuel Gauge/Sender Assembly Replacement Original - February, 1998 Dealer Letter Attachment I ^ Administrative Information ^ Refund Codes Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Supplement # 1 - April, 1998 Supplement # 2 - November, 1998 Revised Expiration Date For Owner Notification Program 98B17 - Fuel Gauge/sender Replacement ^ IMPORTANT INFORMATION OWNER NOTIFICATION PROGRAM 97B17 EXPIRATION DATE ^ Attachments not Applicable ^ Customer Notification Letter not Applicable Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign Fuel Gauge/Sender Assembly > Page 12302 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Affected vehicles on the enclosed list. ^ Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign Fuel Gauge/Sender Assembly > Page 12303 Enter claims using DWE. See ACESII Manual, Sections 5 and 6. OWNER REFUNDS See ACESII Manual, Section 3-63 for submission procedures. For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Program Code - 97B17 Misc. Expense - REFUND Misc. Expense - ADMIN. Misc. Expense - 0.2 Hr. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order fuel sender assemblies and the gaskets through normal processing channels. PART NUMBER/DESCRIPTION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign Fuel Gauge/Sender Assembly > Page 12304 Fuel Sender Assembly - NOTE: Some of the following applications will require gaskets to be ordered in addition to the sender assemblies. DEALER PRICE For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. CLAIMS PREPARATION Enter using DWE. Use code information shown below: ^ Program Code - 97B17 ^ Labor Operation Code - See Above See Sections 5 and 6 of the ACESII Manual for detailed instructions Affected Vehicle and Warning Information AFFECTED VEHICLES: CERTAIN 1997 TAURUS/SABLE, EXPLORER/MOUNTAINEER, EXPEDITION, MUSTANG AND 1998 WINDSTAR WARNING DO NOT SWALLOW GASOLINE, THESE FUELS ARE HIGHLY TOXIC AND IF SWALLOWED CAN CAUSE DEATH OR PERMANENT INJURY, SWALLOWING METHANOL CAN ALSO CAUSE BLINDNESS. CALL A PHYSICIAN IMMEDIATELY TO TREAT ANYONE WHO HAS SWALLOWED FUEL METHANOL OR FUEL ETHANOL. VOMITING SHOULD BE INDUCED BY OR UNDER THE DIRECTION OF A PHYSICIAN OR POISON CONTROL CENTER. BE AWARE THAT THE ONSET OF POTENTIAL ILL HEALTH EFFECTS MAY BE DELAYED. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign Fuel Gauge/Sender Assembly > Page 12305 WARNING AVOID INHALING FUEL VAPORS. INHALING TOO MUCH FUEL VAPOR CAN LEAD TO EYE AND RESPIRATORY TRACT IRRITATION. IN SEVERE CASES, EXCESSIVE OR PROLONGED BREATHING OF FUEL VAPORS CAN CAUSE SERIOUS ILLNESS AND PERMANENT INJURY SUCH AS BLINDNESS. WARNING AVOID GETTING GASOLINE IN YOUR EYES. IF YOU GET ANY FUEL IN YOUR EYES, REMOVE CONTRACT LENSES (IF WORN), FLUSH IMMEDIATELY WITH PLENTY OF WATER FOR AT LEAST 15 MINUTES AND SEEK MEDICAL ATTENTION. WARNING IF YOU GET ANY FUEL ON YOUR SKIN, WASH WITH SOAP AND WATER. REPEATED OR PROLONGED SKIN CONTACT WITH FUEL LIQUID OR VAPOR CAUSES SKIN IRRITATION. WARNING DO NOT OPERATE ENGINE OR SMOKE WHILE REFUELING. Expedition 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Raise and support vehicle. 4. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 5. Disconnect fuel filler and vent hoses from fuel tank. Refer to Figure 1. 6. Disconnect rear EVAP hose from top of fuel tank. See Figure 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign Fuel Gauge/Sender Assembly > Page 12306 7. Support fuel tank with adjustable jack. 8. Remove fuel tank straps retaining bolts. The skid plate, fuel tank and straps will be removed as an assembly. 9. Slightly lower fuel tank. 10. Disconnect fuel supply and return lines from top of fuel tank. See Figure 2. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign Fuel Gauge/Sender Assembly > Page 12307 11. Disconnect fuel pump electrical connector, located between the side of the fuel tank and the frame rail. See Figure 3. 12. Slightly lower fuel tank again. 13. Disconnect front EVAP hose from top of fuel tank. 14. Remove fuel tank from vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign Fuel Gauge/Sender Assembly > Page 12308 15. Clean area around fuel pump to prevent foreign material from entering fuel tank. Refer to Figure 4. 16. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel pump during reassembly. 17. Remove fuel pump lock-ring, then remove fuel pump. See Figure 4. 18. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign Fuel Gauge/Sender Assembly > Page 12309 19. Disconnect fuel sender electrical connectors. Refer to Figure 5. 20. Remove fuel sender retaining screws, then remove fuel sender. See Figure 5. 21. Install new fuel sender on fuel pump. Tighten screws to 2 Nm (18 lb/in). 22. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 23. Clean fuel pump-to-gas tank mating surface. 24. Install new seal onto fuel pump-to-gas tank mating surface. 25. Install fuel pump. Align marks made during disassembly. Tighten lock-ring to 44 Nm (33 lb/ft). 26. Position fuel tank under vehicle. 27. Raise fuel tank enough to connect front EVAP hose. 28. Connect front EVAP hose. 29. Raise fuel tank enough to connect fuel lines. 30. Connect fuel supply and return lines. 31. Connect fuel pump electrical connector. 32. Raise fuel tank to installed position. 33. Install fuel tank strap retaining bolts. Tighten bolts to 46-63 Nm (33-46 lb/ft). 34. Remove jack. 35. Connect rear EVAP hose to top of fuel tank. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign Fuel Gauge/Sender Assembly > Page 12310 36. Connect fuel filler and vent hoses to fuel tank. 37. Refill fuel tank. It may be necessary to refill fuel tank before connecting filler hose. 38. Lower vehicle. 39. Connect battery negative cable, then remove memory saver. 40. Stan and run engine. 41. Raise vehicle. 42. Inspect fuel system for leaks. 43. Lower vehicle. Explorer/Mountaineer 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Raise and support vehicle. 4. Remove skid plate retaining bolts, then the skid plate. 5. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 6. Support fuel tank with adjustable jack. 7. Disconnect fuel filler and vent hoses from fuel tank. 8. Remove fuel tank strap retaining bolt. 9. Remove fuel tank-to-front support bracket retaining bolts. 10. Slightly lower fuel tank. Push fuel tank back until lip of tank clears support bracket. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign Fuel Gauge/Sender Assembly > Page 12311 11. Disconnect fuel supply, return and vapor lines from top of fuel tank. See Figure 6. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign Fuel Gauge/Sender Assembly > Page 12312 12. Disconnect fuel pump electrical connector, located in frame rail. See Figure 7. 13. Remove fuel tank from vehicle. 14. Disconnect fuel tank pressure transducer electrical connector. Refer to Figure 8. 15. Clean area around fuel pump to prevent foreign material from entering fuel tank. 16. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel pump during assembly. 17. Remove fuel pump retaining screws, then remove fuel pump. See Figure 8. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign Fuel Gauge/Sender Assembly > Page 12313 18. Disconnect fuel sender electrical connectors. Refer to Figure 9. 19. Remove fuel sender retaining screws, then remove fuel sender. See Figure 9. 20. Install new fuel sender on fuel pump. Tighten screws to 2 Nm (18 lb/in). 21. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 22. Clean fuel pump-to-gas tank mating surface. 23. Install fuel pump. Align marks made during disassembly. Tighten retaining screws to 9-12 Nm (80-107 lb/in). 24. Connect fuel tank pressure transducer electrical connector. 25. Position fuel tank under vehicle. 26. Raise fuel tank enough to connect fuel lines. 27. Connect fuel supply and return lines. 28. Connect fuel pump electrical connector. 29. Position fuel tank in installed position. 30. Install fuel tank-to-front support bracket retaining bolts. Tighten bolts to 34-46 Nm (25-34 lb/ft). 31. Install fuel tank strap retaining bolt. Tighten bolts to 34-46 Nm (25-34 lb/ft). 32. Remove jack. 33. Connect fuel filler and vent hoses to fuel tank. 34. Install skid plate. Torque retaining bolts to 34-46 Nm (25-34 lb/ft). 35. Lower vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign Fuel Gauge/Sender Assembly > Page 12314 36. Fill fuel tank. 37. Connect battery negative cable, then remove memory saver. 38. Start and run engine. 39. Raise vehicle. 40. Inspect fuel system for leaks. 41. Lower vehicle. Mustang 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 4. Remove fuel filler pipe retainers from gas cap side of fuel filler pipe. 5. Raise and support vehicle. 6. Remove screw retaining fuel filler pipe retainer to fuel tank flange.Refer to Figure 10. 7. Remove fuel filler pipe rubber weather boot from inner fender well. See Figure 10. 8. Support fuel tank with adjustable jack. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign Fuel Gauge/Sender Assembly > Page 12315 9. Disconnect fuel pump electrical connector. See Figure 11. 10. Remove fuel tank straps retaining bolts. 11. Slightly lower fuel tank. 12. With an assistant's help, remove filler pipe from fuel tank. The filler pipe is friction fit into the fuel tank, the filler pipe will have to be walked out of the fuel tank. See Figure 12. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign Fuel Gauge/Sender Assembly > Page 12316 13. Disconnect fuel supply, return and vapor lines. See Figure 13. 14. Disconnect fuel sender electrical connector. Refer to Figure 14. 15. Remove fuel tank from vehicle. 16. Clean area around fuel sender to prevent foreign material from entering fuel tank. 17. Place alignment mark across fuel sender and fuel tank. This will assure correct alignment of fuel sender during assembly. 18. Remove fuel sender lock-ring. See Figure 14. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign Fuel Gauge/Sender Assembly > Page 12317 19. Remove and discard fuel sender. 20. Remove and discard fuel sender seal. 21. Lubricate and install new fuel sender seal. 22. Install new fuel sender. Align mark made during disassembly. Tighten lock ring until it contact stops. 23. Connect fuel sender electrical connector. 24. Raise fuel tank enough to connect fuel lines. 25. Connect fuel supply, return and vapor lines. 26. Install fuel filler pipe in fuel tank. 27. Position fuel tank in installed position. 28. Install fuel tank straps. Tighten retaining bolts to 30-40 Nm (22-30 lb/ft). 29. Remove adjustable jack. 30. Connect fuel pump electrical connector. 31. Install fuel filler pipe rubber weather boot to inner fender well. 32. Install screw retaining fuel filler pipe retainer to fuel tank flange. Tighten screw to 7.3-9.0 Nm (65-80 lb/in). 33. Lower vehicle. 34. Install fuel filler pipe retainers to gas cap side of fuel filler pipe. 35. Fill fuel tank. 36. Connect battery negative cable, then remove memory saver. 37. Start and run engine. 38. Raise vehicle. 39. Inspect fuel system for leaks. 40. Lower vehicle. Taurus/Sable 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 4. Raise and support vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign Fuel Gauge/Sender Assembly > Page 12318 5. Disconnect fuel filler and vent hoses from fuel tank. See Figure 15. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign Fuel Gauge/Sender Assembly > Page 12319 6. Disconnect fuel supply and return lines. Refer to Figure 16. 7. Disconnect fuel pump electrical connector. See Figure 16. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign Fuel Gauge/Sender Assembly > Page 12320 8. Disconnect fuel vapor line. See Figure 17. 9. Support fuel tank with adjustable jack. 10. Remove fuel tank strap retaining bolts. 11. Remove fuel tank from vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign Fuel Gauge/Sender Assembly > Page 12321 12. Detach fuel pump wiring harness and fuel lines from fuel tank. Refer to Figure 18. 13. Clean area around fuel pump to prevent foreign material from entering fuel tank. 14. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel pump during assembly. 15. Disconnect fuel pressure transducer electrical connector. See Figure 18. 16. Remove fuel pump lock-ring. 17. Remove fuel pump. 18. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign Fuel Gauge/Sender Assembly > Page 12322 19. Disconnect fuel sender electrical connectors. Refer to Figure 19. 20. Remove fuel sender retaining screw, then remove fuel sender. See Figure 19. 21. Install new fuel sender on fuel pump. Tighten screw to 1 Nm (9 lb/in). 22. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 23. Clean fuel pump-to-gas tank mating surface. 24. Lubricate and install new fuel pump gasket. 25. Install fuel pump. Align marks made during disassembly. Tighten lock ring until it contacts stops. 26. Install fuel pump wiring harness and fuel lines on fuel tank assembly. 27. Connect fuel pressure transducer electrical connector. 28. Install fuel tank in vehicle. Tighten fuel tank straps to 30-40 Nm (22-30 lb/ft). 29. Remove adjustable jack. 30. Connect fuel pump electrical connector. 31. Connect fuel supply, return and vapor lines. 32. Connect fuel filler and vent hoses to fuel tank. 33. Lower vehicle. 34. Fill fuel tank. 35. Connect battery negative cable, then remove memory saver. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign Fuel Gauge/Sender Assembly > Page 12323 36. Start and run engine. 37. Raise vehicle. 38. Inspect fuel system for leaks. 39. Lower vehicle. Windstar 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 4. Raise and support vehicle. 5. Support fuel tank with adjustable jack. 6. Disconnect fuel filler and vent hoses from fuel tank. 7. Disconnect fuel supply, return and vapor lines. See Figure 20. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign Fuel Gauge/Sender Assembly > Page 12324 8. Disconnect fuel pump electrical connector. See Figure 21. 9. Remove fuel tank straps retaining bolts. 10. Remove fuel tank from vehicle. 11. Clean area around fuel pump to prevent foreign material from entering fuel tank. 12. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel during assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign Fuel Gauge/Sender Assembly > Page 12325 13. Detach fuel lines from routing clips and tie strap. See Figure 22. 14. Remove fuel pump lock-ring. 15. Remove fuel pump. 16. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign Fuel Gauge/Sender Assembly > Page 12326 17. Disconnect fuel sender electrical connectors. Refer to Figure 23. 18. Remove fuel sender retaining screw, then remove fuel sender. See Figure 23. 19. Install new fuel sender on fuel pump. Tighten screw to 1 Nm (9 lb/in). 20. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 21. Clean fuel pump-to-gas tank mating surface. 22. Install new fuel pump gasket. 23. Install fuel pump. Align marks made during disassembly. Tighten lock ring until it contact stops. 24. Attach fuel lines to routing clips and install tie strap. Connect fuel lines to fuel pump. Connect electrical connector to pump/sender. 25. Install fuel tank in vehicle. Tighten fuel tank straps to 41-54 Nm (31-39 lb/ft). 26. Connect fuel pump electrical connector. 27. Connect fuel supply, return and vapor lines. 28. Connect fuel filler and vent hoses to fuel tank. 29. Remove adjustable jack. 30. Lower vehicle. 31. Fill fuel tank. 32. Connect battery negative cable, then remove memory saver. 33. Start and run engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign Fuel Gauge/Sender Assembly > Page 12327 34. Raise vehicle. 35. Inspect fuel system for leaks. 36. Lower vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign Fuel Gauge/Sender Assembly > Page 12328 Supplement # 1 - Attachment II LABOR ALLOWANCES Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign Fuel Gauge/Sender Assembly > Page 12329 PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order fuel sender assemblies and the gaskets through normal processing channels. PART NUMBER/DESCRIPTION Fuel Sender Assembly - NOTE: Some of the following applications will require gaskets to be ordered in addition to the sender assemblies. NOTE: Kit Codes "AA" & "BB" are not used. Warning For 1997 Expedition FUEL SENDER REPLACEMENT SUPPLEMENT FOR 1997 EXPEDITION WARNING DO NOT SWALLOW GASOLINE, THESE FUELS ARE HIGHLY TOXIC AND IF SWALLOWED CAN CAUSE DEATH OR PERMANENT INJURY, SWALLOWING METHANOL CAN ALSO CAUSE BLINDNESS. CALL A PHYSICIAN IMMEDIATELY TO TREAT ANYONE WHO HAS SWALLOWED FUEL METHANOL OR FUEL ETHANOL. VOMITING SHOULD BE INDUCED BY OR UNDER THE DIRECTION OF A PHYSICIAN OR POISON CONTROL CENTER. BE AWARE THAT THE ONSET OF POTENTIAL ILL HEALTH EFFECTS MAY BE DELAYED. WARNING AVOID INHALING FUEL VAPORS. INHALING TOO MUCH FUEL VAPOR CAN LEAD TO EYE AND RESPIRATORY TRACT IRRITATION. IN SEVERE CASES, EXCESSIVE OR PROLONGED BREATHING OF FUEL VAPORS CAN CAUSE SERIOUS ILLNESS AND PERMANENT INJURY SUCH AS BLINDNESS. WARNING AVOID GETTING GASOLINE IN YOUR EYES. IF YOU GET ANY FUEL IN YOUR EYES, REMOVE CONTACT LENSES (IF WORN), FLUSH IMMEDIATELY WITH PLENTY OF WATER FOR AT LEAST 15 MINUTES AND SEEK MEDICAL ATTENTION. WARNING IF YOU GET ANY FUEL ON YOUR SKIN, WASH WITH SOAP AND WATER. REPEATED OR PROLONGED SKIN CONTACT WITH FUEL LIQUID OR VAPOR CAUSES SKIN IRRITATION. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign Fuel Gauge/Sender Assembly > Page 12330 WARNING DO NOT OPERATE ENGINE OR SMOKE WHILE REFUELING. Expedition 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Raise and support vehicle. 4. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 5. Disconnect fuel filler and vent hoses from fuel tank. Refer to Figure 1. 6. Disconnect rear EVAP hose from top of fuel tank. See Figure 1. 7. Support fuel tank with adjustable jack. 8. Remove fuel tank straps retaining bolts. The skid plate, fuel tank and straps will be removed as an assembly. 9. Slightly lower fuel tank. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign Fuel Gauge/Sender Assembly > Page 12331 10. Disconnect fuel supply and return lines from top of fuel tank. See Figure 2. 11. Disconnect fuel pump electrical connector, located between the side of the fuel tank and the frame rail. See Figure 3. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign Fuel Gauge/Sender Assembly > Page 12332 12. Slightly lower fuel tank again. 13. Disconnect front EVAP hose from top of fuel tank. 14. Remove fuel tank from vehicle. 15. Clean area around fuel pump to prevent foreign material from entering fuel tank. Refer to Figure 4. 16. Place alignment mark across fuel pump and fuel tank. This will correctly align the fuel pump during reassembly. 17. Remove fuel pump lock-ring, then remove fuel pump. See Figure 4. 18. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign Fuel Gauge/Sender Assembly > Page 12333 19. Disconnect fuel sender electrical connectors. Refer to Figure 5. 20. Remove fuel sender retaining screws, then remove fuel sender. See Figure 5. NOTE: On some vehicles this step may have already been performed. CAUTION Do not cut the main 14 gauge pump ground wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign Fuel Gauge/Sender Assembly > Page 12334 21. Cut a section out of the 18 gauge black grounding wire. See Figure 6. Discard removed black wire. 22. Install new fuel sender on the fuel pump. Tighten screws to 2 Nm (18 lb/in). Note the revised orientation of the float. NOTE: There are two (2) different terminal end types used on the fuel sender ground wire, a box terminal or a ring terminal. These terminal ends are connected to different locations on the fuel sender. 23. Connect fuel sender electrical connectors as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign Fuel Gauge/Sender Assembly > Page 12335 ^ Connect box type terminal end ground wire to location shown in Figure 7. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign Fuel Gauge/Sender Assembly > Page 12336 ^ Connect ring type terminal end ground wire to location shown in Figure 8. ^ Reconnect yellow wire to pump sending unit harness. 24. Clean fuel pump-to-gas tank mating surface. 25. Install new seal onto fuel pump-to-gas tank mating surface. 26. Install fuel pump. Align marks made during disassembly. Tighten lock-ring to 44 Nm (33 lb/ft). 27. Position fuel tank under vehicle. 28. Raise fuel tank enough to connect front EVAP hose. 29. Connect front EVAP hose. 30. Raise fuel tank enough to connect fuel lines. 31. Connect fuel supply and return lines. 32. Connect fuel pump electrical connector. 33. Raise fuel tank to installed position. 34. Install fuel tank strap retaining bolts. Tighten bolts to 46-63 Nm (33-46 lb/ft). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Recalls: > 97B17 > Feb > 98 > Campaign Fuel Gauge/Sender Assembly > Page 12337 35. Remove jack. 36. Connect rear EVAP hose to top of fuel tank. 37. Connect fuel filler and vent hoses to fuel tank. 38. Refill fuel tank. It may be necessary to refill fuel tank before connecting filler hose. 39. Lower vehicle. 40. Connect battery negative cable, then remove memory saver. 41. Stan and run engine. 42. Raise vehicle. 43. Inspect fuel system for leaks. 44. Lower vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Component Information > Locations > Front Ride Height Sensor: Locations Front Body View The Front Height Sensor is located behind left running broad. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Component Information > Locations > Front > Page 12341 Ride Height Sensor: Locations Rear Body View The Rear Height Sensor is located at rear floor panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Component Information > Description and Operation > Four Wheel Air Suspension Ride Height Sensor: Description and Operation Four Wheel Air Suspension Two height sensors are mounted on the vehicle. The sensors send a voltage signal to the control module. The output ranges from approximately 4.75 volts at minimum height (when the vehicle is low or in full jounce), to 0.25 volts at maximum height (when the vehicle is high or in full rebound). The sensors have a useable range of 80 mm (3 in) compared to total suspension travel of 200-250 mm (8-10 in) at the wheel. Therefore, the sensors are mounted to the suspension at a point where full suspension travel at the wheel is relative to 80 mm (3 in) of travel at the height sensor. The front height sensor upper socket is attached to the bracket to the frame at the upper control arm mounting area and the lower height sensor socket is attached to the upper control arm bracket. The rear height sensor is attached between the No. 5 frame crossmember (upper socket) and the panhard rod (lower socket). Replace a sensor as a unit. When the height sensor gets shorter the vehicle is lowered and this will cause the air compressor to turn on and pump compressed air to the system. When the sensor gets longer the vehicle is being raised and this will cause the air to be vented from the system to lower the vehicle to its trim height level. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Component Information > Description and Operation > Four Wheel Air Suspension > Page 12344 Ride Height Sensor: Description and Operation Rear Air Suspension When the height sensor gets shorter the rear of the vehicle is lowered and this will cause the air compressor to turn on and pump compressed air to the air springs. When the sensor gets longer the rear of the vehicle is being raised and this will cause the air to be vented from the air springs to lower the vehicle back to its trim height level. One height sensor is mounted on the vehicle. The sensor sends a voltage signal to the control module. The output ranges from approximately 4.75 volts at minimum height (when the vehicle is low or in full jounce), to 0.25 volts at maximum height (when the vehicle is high or in full rebound). The sensor has a useable range of 80 mm (3 in) compared to total suspension travel of 200-250 mm (8 to 10 in) at the wheel. Therefore, the sensor is mounted to the suspension at a point where full rear suspension travel at the wheel is relative to 80 mm of travel at the height sensor. The rear height sensor is attached between the No. 5 frame crossmember (upper socket) and the panhard rod (lower socket). Replace the sensor as a unit. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Component Information > Adjustments > Inflate and Deflate the Air Suspension System Ride Height Sensor: Adjustments Inflate and Deflate the Air Suspension System 1. Turn the ignition to the run position. WARNING: DO NOT REMOVE AN AIR SPRING UNDER ANY CIRCUMSTANCES WHEN THERE IS PRESSURE IN THE AIR SPRING. DO NOT REMOVE ANY COMPONENTS SUPPORTING AN AIR SPRING WITHOUT EITHER EXHAUSTING THE AIR OR PROVIDING SUPPORT FOR THE AIR SPRING TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. 2. Connect NGS tester to vehicle. 3. Select 1997 4.6L/5.4L Expedition 4WAS module. 4. Select "Air Suspension Control Mode" under "Active Command Modes" menu. (1) Select "VENT REAR" to deflate rear air springs. (2) Select "LIFT REAR" to inflate rear air springs. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Component Information > Adjustments > Inflate and Deflate the Air Suspension System > Page 12347 Ride Height Sensor: Adjustments Rear Height Resetting Procedure 1. Turn ignition key on. 2. Connect NGS tester to the vehicle. 3. Select 1997 4.6L/5.4L Expedition-4WAS module. 4. Measure vehicle rear height (driver side) from the bottom of the frame to the rear jounce bumper bolt rear side of head base. 5. By using NGS tester "active command modes", adjust rear height to 146.8 +/- 2 mm by moving rear of the vehicle down "VENT REAR" or moving rear of the vehicle up "LIFT REAR." 6. Monitor on the right side of the NGS screen rear height sensor voltage. 7. Loosen the ball stud nut on rear height sensor bracket on track bar and adjust by moving with height sensor up or down until rear height sensor voltage is 2.61 +/- 0.03 volt. 8. Tighten nut to specifications. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Component Information > Adjustments > Page 12348 Ride Height Sensor: Service and Repair REMOVAL 1. Raise and support the vehicle. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO S O MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Remove the air suspension height sensor. (1) Disconnect electrical connector. (2) Depress the metal retaining tabs and remove the air suspension height sensor from the ball studs. NOTE: The air suspension height sensor has a plastic harness retainer to suspension that must be unclipped prior to removal. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Gauge Sender: All Technical Service Bulletins Fuel Gauge - Erratic and/or Inaccurate Readings Article No. 97-9-16 04/28/97 GAUGES - FUEL - ERRATIC AND/OR INACCURATE READINGS - VEHICLES BUILT THROUGH 3/97 LIGHT TRUCK: 1997 EXPEDITION ISSUE: The fuel gauge may operate erratically and/or have inaccurate readings. This may be caused by the sensing float being positioned at the extreme aft of the fuel tank. ACTION: Replace the fuel pump and sender assembly with a revised pump and sender. The revised pump and sender has a repositioned sensor assembly to bring the float assembly closer to the center of the fuel tank. This should reduce the possibility of inaccurate and erratic readings. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the fuel tank as outlined in Section 310-01 in the 1997 Expedition Workshop Manual. 2. Remove the fuel pump and sender assembly as outlined in Section 310-01 of the Workshop Manual. NOTE: THERE IS NO NEED TO REMOVE THE SENDING UNIT FROM THE REMOVED PUMP. THE REPLACEMENT PUMP HAS A NEW SENDER FITTED ALREADY. THIS SENDER IS ORIENTED DIFFERENTLY FROM THE REMOVED PART. THIS WILL PUT THE FLOAT CLOSER TO THE CENTER OF THE TANK. 3. Remove the pressure transducer from the removed pump and install it onto the new pump. Make sure the electrical connection is made. 4. Using a new green seal (included with the pump), reinstall the pump and sender into the tank as outlined in Section 310-01 of the Workshop Manual. 5. Reinstall the fuel tank as outlined in Section 310-01 of the Workshop Manual. NOTE: WHEN THE BATTERY IS DISCONNECTED AND RECONNECTED, SOME ABNORMAL DRIVE SYMPTOMS MAY OCCUR WHILE THE VEHICLE RELEARNS ITS ADAPTIVE STRATEGY. THE VEHICLE MAY NEED TO BE DRIVEN 16 km (10 MILES) OR MORE TO RELEARN THE STRATEGY. PART NUMBER PART NAME F75Z-9H307-KC Fuel Pump And Sender Assembly (4X4) F75Z-9H307-LC Fuel Pump And Sender Assembly (4X2 Normal Suspension) F75Z-9H307-MC Fuel Pump And Sender Assembly (4X2 Air Suspension) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 970916A Replace Fuel Pump And 1.5 Hrs. Sender Assembly DEALER CODING CONDITION BASIC PART NO. CODE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 12354 9K007 36 OASIS CODES: 204000, 204200 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 962618 > Dec > 96 > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly Technical Service Bulletin # 97B17 Date: 980201 Campaign - Fuel Gauge/Sender Assembly 97517 OWNER NOTIFICATION PROGRAM Fuel Gauge/Sender Assembly Replacement Original - February, 1998 Dealer Letter Attachment I ^ Administrative Information ^ Refund Codes Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Supplement # 1 - April, 1998 Supplement # 2 - November, 1998 Revised Expiration Date For Owner Notification Program 98B17 - Fuel Gauge/sender Replacement ^ IMPORTANT INFORMATION OWNER NOTIFICATION PROGRAM 97B17 EXPIRATION DATE ^ Attachments not Applicable ^ Customer Notification Letter not Applicable Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 962618 > Dec > 96 > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12363 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Affected vehicles on the enclosed list. ^ Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 962618 > Dec > 96 > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12364 Enter claims using DWE. See ACESII Manual, Sections 5 and 6. OWNER REFUNDS See ACESII Manual, Section 3-63 for submission procedures. For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Program Code - 97B17 Misc. Expense - REFUND Misc. Expense - ADMIN. Misc. Expense - 0.2 Hr. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order fuel sender assemblies and the gaskets through normal processing channels. PART NUMBER/DESCRIPTION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 962618 > Dec > 96 > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12365 Fuel Sender Assembly - NOTE: Some of the following applications will require gaskets to be ordered in addition to the sender assemblies. DEALER PRICE For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. CLAIMS PREPARATION Enter using DWE. Use code information shown below: ^ Program Code - 97B17 ^ Labor Operation Code - See Above See Sections 5 and 6 of the ACESII Manual for detailed instructions Affected Vehicle and Warning Information AFFECTED VEHICLES: CERTAIN 1997 TAURUS/SABLE, EXPLORER/MOUNTAINEER, EXPEDITION, MUSTANG AND 1998 WINDSTAR WARNING DO NOT SWALLOW GASOLINE, THESE FUELS ARE HIGHLY TOXIC AND IF SWALLOWED CAN CAUSE DEATH OR PERMANENT INJURY, SWALLOWING METHANOL CAN ALSO CAUSE BLINDNESS. CALL A PHYSICIAN IMMEDIATELY TO TREAT ANYONE WHO HAS SWALLOWED FUEL METHANOL OR FUEL ETHANOL. VOMITING SHOULD BE INDUCED BY OR UNDER THE DIRECTION OF A PHYSICIAN OR POISON CONTROL CENTER. BE AWARE THAT THE ONSET OF POTENTIAL ILL HEALTH EFFECTS MAY BE DELAYED. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 962618 > Dec > 96 > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12366 WARNING AVOID INHALING FUEL VAPORS. INHALING TOO MUCH FUEL VAPOR CAN LEAD TO EYE AND RESPIRATORY TRACT IRRITATION. IN SEVERE CASES, EXCESSIVE OR PROLONGED BREATHING OF FUEL VAPORS CAN CAUSE SERIOUS ILLNESS AND PERMANENT INJURY SUCH AS BLINDNESS. WARNING AVOID GETTING GASOLINE IN YOUR EYES. IF YOU GET ANY FUEL IN YOUR EYES, REMOVE CONTRACT LENSES (IF WORN), FLUSH IMMEDIATELY WITH PLENTY OF WATER FOR AT LEAST 15 MINUTES AND SEEK MEDICAL ATTENTION. WARNING IF YOU GET ANY FUEL ON YOUR SKIN, WASH WITH SOAP AND WATER. REPEATED OR PROLONGED SKIN CONTACT WITH FUEL LIQUID OR VAPOR CAUSES SKIN IRRITATION. WARNING DO NOT OPERATE ENGINE OR SMOKE WHILE REFUELING. Expedition 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Raise and support vehicle. 4. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 5. Disconnect fuel filler and vent hoses from fuel tank. Refer to Figure 1. 6. Disconnect rear EVAP hose from top of fuel tank. See Figure 1. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 962618 > Dec > 96 > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12367 7. Support fuel tank with adjustable jack. 8. Remove fuel tank straps retaining bolts. The skid plate, fuel tank and straps will be removed as an assembly. 9. Slightly lower fuel tank. 10. Disconnect fuel supply and return lines from top of fuel tank. See Figure 2. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 962618 > Dec > 96 > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12368 11. Disconnect fuel pump electrical connector, located between the side of the fuel tank and the frame rail. See Figure 3. 12. Slightly lower fuel tank again. 13. Disconnect front EVAP hose from top of fuel tank. 14. Remove fuel tank from vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 962618 > Dec > 96 > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12369 15. Clean area around fuel pump to prevent foreign material from entering fuel tank. Refer to Figure 4. 16. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel pump during reassembly. 17. Remove fuel pump lock-ring, then remove fuel pump. See Figure 4. 18. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 962618 > Dec > 96 > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12370 19. Disconnect fuel sender electrical connectors. Refer to Figure 5. 20. Remove fuel sender retaining screws, then remove fuel sender. See Figure 5. 21. Install new fuel sender on fuel pump. Tighten screws to 2 Nm (18 lb/in). 22. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 23. Clean fuel pump-to-gas tank mating surface. 24. Install new seal onto fuel pump-to-gas tank mating surface. 25. Install fuel pump. Align marks made during disassembly. Tighten lock-ring to 44 Nm (33 lb/ft). 26. Position fuel tank under vehicle. 27. Raise fuel tank enough to connect front EVAP hose. 28. Connect front EVAP hose. 29. Raise fuel tank enough to connect fuel lines. 30. Connect fuel supply and return lines. 31. Connect fuel pump electrical connector. 32. Raise fuel tank to installed position. 33. Install fuel tank strap retaining bolts. Tighten bolts to 46-63 Nm (33-46 lb/ft). 34. Remove jack. 35. Connect rear EVAP hose to top of fuel tank. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 962618 > Dec > 96 > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12371 36. Connect fuel filler and vent hoses to fuel tank. 37. Refill fuel tank. It may be necessary to refill fuel tank before connecting filler hose. 38. Lower vehicle. 39. Connect battery negative cable, then remove memory saver. 40. Stan and run engine. 41. Raise vehicle. 42. Inspect fuel system for leaks. 43. Lower vehicle. Explorer/Mountaineer 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Raise and support vehicle. 4. Remove skid plate retaining bolts, then the skid plate. 5. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 6. Support fuel tank with adjustable jack. 7. Disconnect fuel filler and vent hoses from fuel tank. 8. Remove fuel tank strap retaining bolt. 9. Remove fuel tank-to-front support bracket retaining bolts. 10. Slightly lower fuel tank. Push fuel tank back until lip of tank clears support bracket. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 962618 > Dec > 96 > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12372 11. Disconnect fuel supply, return and vapor lines from top of fuel tank. See Figure 6. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 962618 > Dec > 96 > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12373 12. Disconnect fuel pump electrical connector, located in frame rail. See Figure 7. 13. Remove fuel tank from vehicle. 14. Disconnect fuel tank pressure transducer electrical connector. Refer to Figure 8. 15. Clean area around fuel pump to prevent foreign material from entering fuel tank. 16. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel pump during assembly. 17. Remove fuel pump retaining screws, then remove fuel pump. See Figure 8. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 962618 > Dec > 96 > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12374 18. Disconnect fuel sender electrical connectors. Refer to Figure 9. 19. Remove fuel sender retaining screws, then remove fuel sender. See Figure 9. 20. Install new fuel sender on fuel pump. Tighten screws to 2 Nm (18 lb/in). 21. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 22. Clean fuel pump-to-gas tank mating surface. 23. Install fuel pump. Align marks made during disassembly. Tighten retaining screws to 9-12 Nm (80-107 lb/in). 24. Connect fuel tank pressure transducer electrical connector. 25. Position fuel tank under vehicle. 26. Raise fuel tank enough to connect fuel lines. 27. Connect fuel supply and return lines. 28. Connect fuel pump electrical connector. 29. Position fuel tank in installed position. 30. Install fuel tank-to-front support bracket retaining bolts. Tighten bolts to 34-46 Nm (25-34 lb/ft). 31. Install fuel tank strap retaining bolt. Tighten bolts to 34-46 Nm (25-34 lb/ft). 32. Remove jack. 33. Connect fuel filler and vent hoses to fuel tank. 34. Install skid plate. Torque retaining bolts to 34-46 Nm (25-34 lb/ft). 35. Lower vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 962618 > Dec > 96 > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12375 36. Fill fuel tank. 37. Connect battery negative cable, then remove memory saver. 38. Start and run engine. 39. Raise vehicle. 40. Inspect fuel system for leaks. 41. Lower vehicle. Mustang 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 4. Remove fuel filler pipe retainers from gas cap side of fuel filler pipe. 5. Raise and support vehicle. 6. Remove screw retaining fuel filler pipe retainer to fuel tank flange.Refer to Figure 10. 7. Remove fuel filler pipe rubber weather boot from inner fender well. See Figure 10. 8. Support fuel tank with adjustable jack. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 962618 > Dec > 96 > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12376 9. Disconnect fuel pump electrical connector. See Figure 11. 10. Remove fuel tank straps retaining bolts. 11. Slightly lower fuel tank. 12. With an assistant's help, remove filler pipe from fuel tank. The filler pipe is friction fit into the fuel tank, the filler pipe will have to be walked out of the fuel tank. See Figure 12. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 962618 > Dec > 96 > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12377 13. Disconnect fuel supply, return and vapor lines. See Figure 13. 14. Disconnect fuel sender electrical connector. Refer to Figure 14. 15. Remove fuel tank from vehicle. 16. Clean area around fuel sender to prevent foreign material from entering fuel tank. 17. Place alignment mark across fuel sender and fuel tank. This will assure correct alignment of fuel sender during assembly. 18. Remove fuel sender lock-ring. See Figure 14. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 962618 > Dec > 96 > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12378 19. Remove and discard fuel sender. 20. Remove and discard fuel sender seal. 21. Lubricate and install new fuel sender seal. 22. Install new fuel sender. Align mark made during disassembly. Tighten lock ring until it contact stops. 23. Connect fuel sender electrical connector. 24. Raise fuel tank enough to connect fuel lines. 25. Connect fuel supply, return and vapor lines. 26. Install fuel filler pipe in fuel tank. 27. Position fuel tank in installed position. 28. Install fuel tank straps. Tighten retaining bolts to 30-40 Nm (22-30 lb/ft). 29. Remove adjustable jack. 30. Connect fuel pump electrical connector. 31. Install fuel filler pipe rubber weather boot to inner fender well. 32. Install screw retaining fuel filler pipe retainer to fuel tank flange. Tighten screw to 7.3-9.0 Nm (65-80 lb/in). 33. Lower vehicle. 34. Install fuel filler pipe retainers to gas cap side of fuel filler pipe. 35. Fill fuel tank. 36. Connect battery negative cable, then remove memory saver. 37. Start and run engine. 38. Raise vehicle. 39. Inspect fuel system for leaks. 40. Lower vehicle. Taurus/Sable 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 4. Raise and support vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 962618 > Dec > 96 > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12379 5. Disconnect fuel filler and vent hoses from fuel tank. See Figure 15. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 962618 > Dec > 96 > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12380 6. Disconnect fuel supply and return lines. Refer to Figure 16. 7. Disconnect fuel pump electrical connector. See Figure 16. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 962618 > Dec > 96 > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12381 8. Disconnect fuel vapor line. See Figure 17. 9. Support fuel tank with adjustable jack. 10. Remove fuel tank strap retaining bolts. 11. Remove fuel tank from vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 962618 > Dec > 96 > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12382 12. Detach fuel pump wiring harness and fuel lines from fuel tank. Refer to Figure 18. 13. Clean area around fuel pump to prevent foreign material from entering fuel tank. 14. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel pump during assembly. 15. Disconnect fuel pressure transducer electrical connector. See Figure 18. 16. Remove fuel pump lock-ring. 17. Remove fuel pump. 18. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 962618 > Dec > 96 > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12383 19. Disconnect fuel sender electrical connectors. Refer to Figure 19. 20. Remove fuel sender retaining screw, then remove fuel sender. See Figure 19. 21. Install new fuel sender on fuel pump. Tighten screw to 1 Nm (9 lb/in). 22. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 23. Clean fuel pump-to-gas tank mating surface. 24. Lubricate and install new fuel pump gasket. 25. Install fuel pump. Align marks made during disassembly. Tighten lock ring until it contacts stops. 26. Install fuel pump wiring harness and fuel lines on fuel tank assembly. 27. Connect fuel pressure transducer electrical connector. 28. Install fuel tank in vehicle. Tighten fuel tank straps to 30-40 Nm (22-30 lb/ft). 29. Remove adjustable jack. 30. Connect fuel pump electrical connector. 31. Connect fuel supply, return and vapor lines. 32. Connect fuel filler and vent hoses to fuel tank. 33. Lower vehicle. 34. Fill fuel tank. 35. Connect battery negative cable, then remove memory saver. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 962618 > Dec > 96 > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12384 36. Start and run engine. 37. Raise vehicle. 38. Inspect fuel system for leaks. 39. Lower vehicle. Windstar 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 4. Raise and support vehicle. 5. Support fuel tank with adjustable jack. 6. Disconnect fuel filler and vent hoses from fuel tank. 7. Disconnect fuel supply, return and vapor lines. See Figure 20. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 962618 > Dec > 96 > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12385 8. Disconnect fuel pump electrical connector. See Figure 21. 9. Remove fuel tank straps retaining bolts. 10. Remove fuel tank from vehicle. 11. Clean area around fuel pump to prevent foreign material from entering fuel tank. 12. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel during assembly. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 962618 > Dec > 96 > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12386 13. Detach fuel lines from routing clips and tie strap. See Figure 22. 14. Remove fuel pump lock-ring. 15. Remove fuel pump. 16. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 962618 > Dec > 96 > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12387 17. Disconnect fuel sender electrical connectors. Refer to Figure 23. 18. Remove fuel sender retaining screw, then remove fuel sender. See Figure 23. 19. Install new fuel sender on fuel pump. Tighten screw to 1 Nm (9 lb/in). 20. Connect fuel sender electrical connectors. Make sure wires are routed correctly. 21. Clean fuel pump-to-gas tank mating surface. 22. Install new fuel pump gasket. 23. Install fuel pump. Align marks made during disassembly. Tighten lock ring until it contact stops. 24. Attach fuel lines to routing clips and install tie strap. Connect fuel lines to fuel pump. Connect electrical connector to pump/sender. 25. Install fuel tank in vehicle. Tighten fuel tank straps to 41-54 Nm (31-39 lb/ft). 26. Connect fuel pump electrical connector. 27. Connect fuel supply, return and vapor lines. 28. Connect fuel filler and vent hoses to fuel tank. 29. Remove adjustable jack. 30. Lower vehicle. 31. Fill fuel tank. 32. Connect battery negative cable, then remove memory saver. 33. Start and run engine. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 962618 > Dec > 96 > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12388 34. Raise vehicle. 35. Inspect fuel system for leaks. 36. Lower vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 962618 > Dec > 96 > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12389 Supplement # 1 - Attachment II LABOR ALLOWANCES Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 962618 > Dec > 96 > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12390 PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order fuel sender assemblies and the gaskets through normal processing channels. PART NUMBER/DESCRIPTION Fuel Sender Assembly - NOTE: Some of the following applications will require gaskets to be ordered in addition to the sender assemblies. NOTE: Kit Codes "AA" & "BB" are not used. Warning For 1997 Expedition FUEL SENDER REPLACEMENT SUPPLEMENT FOR 1997 EXPEDITION WARNING DO NOT SWALLOW GASOLINE, THESE FUELS ARE HIGHLY TOXIC AND IF SWALLOWED CAN CAUSE DEATH OR PERMANENT INJURY, SWALLOWING METHANOL CAN ALSO CAUSE BLINDNESS. CALL A PHYSICIAN IMMEDIATELY TO TREAT ANYONE WHO HAS SWALLOWED FUEL METHANOL OR FUEL ETHANOL. VOMITING SHOULD BE INDUCED BY OR UNDER THE DIRECTION OF A PHYSICIAN OR POISON CONTROL CENTER. BE AWARE THAT THE ONSET OF POTENTIAL ILL HEALTH EFFECTS MAY BE DELAYED. WARNING AVOID INHALING FUEL VAPORS. INHALING TOO MUCH FUEL VAPOR CAN LEAD TO EYE AND RESPIRATORY TRACT IRRITATION. IN SEVERE CASES, EXCESSIVE OR PROLONGED BREATHING OF FUEL VAPORS CAN CAUSE SERIOUS ILLNESS AND PERMANENT INJURY SUCH AS BLINDNESS. WARNING AVOID GETTING GASOLINE IN YOUR EYES. IF YOU GET ANY FUEL IN YOUR EYES, REMOVE CONTACT LENSES (IF WORN), FLUSH IMMEDIATELY WITH PLENTY OF WATER FOR AT LEAST 15 MINUTES AND SEEK MEDICAL ATTENTION. WARNING IF YOU GET ANY FUEL ON YOUR SKIN, WASH WITH SOAP AND WATER. REPEATED OR PROLONGED SKIN CONTACT WITH FUEL LIQUID OR VAPOR CAUSES SKIN IRRITATION. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 962618 > Dec > 96 > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12391 WARNING DO NOT OPERATE ENGINE OR SMOKE WHILE REFUELING. Expedition 1. Install memory saver, then disconnect battery negative cable. 2. Remove fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge. ^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure. 3. Raise and support vehicle. 4. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank. 5. Disconnect fuel filler and vent hoses from fuel tank. Refer to Figure 1. 6. Disconnect rear EVAP hose from top of fuel tank. See Figure 1. 7. Support fuel tank with adjustable jack. 8. Remove fuel tank straps retaining bolts. The skid plate, fuel tank and straps will be removed as an assembly. 9. Slightly lower fuel tank. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 962618 > Dec > 96 > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12392 10. Disconnect fuel supply and return lines from top of fuel tank. See Figure 2. 11. Disconnect fuel pump electrical connector, located between the side of the fuel tank and the frame rail. See Figure 3. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 962618 > Dec > 96 > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12393 12. Slightly lower fuel tank again. 13. Disconnect front EVAP hose from top of fuel tank. 14. Remove fuel tank from vehicle. 15. Clean area around fuel pump to prevent foreign material from entering fuel tank. Refer to Figure 4. 16. Place alignment mark across fuel pump and fuel tank. This will correctly align the fuel pump during reassembly. 17. Remove fuel pump lock-ring, then remove fuel pump. See Figure 4. 18. Remove and discard fuel pump seal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 962618 > Dec > 96 > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12394 19. Disconnect fuel sender electrical connectors. Refer to Figure 5. 20. Remove fuel sender retaining screws, then remove fuel sender. See Figure 5. NOTE: On some vehicles this step may have already been performed. CAUTION Do not cut the main 14 gauge pump ground wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 962618 > Dec > 96 > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12395 21. Cut a section out of the 18 gauge black grounding wire. See Figure 6. Discard removed black wire. 22. Install new fuel sender on the fuel pump. Tighten screws to 2 Nm (18 lb/in). Note the revised orientation of the float. NOTE: There are two (2) different terminal end types used on the fuel sender ground wire, a box terminal or a ring terminal. These terminal ends are connected to different locations on the fuel sender. 23. Connect fuel sender electrical connectors as follows: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 962618 > Dec > 96 > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12396 ^ Connect box type terminal end ground wire to location shown in Figure 7. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 962618 > Dec > 96 > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12397 ^ Connect ring type terminal end ground wire to location shown in Figure 8. ^ Reconnect yellow wire to pump sending unit harness. 24. Clean fuel pump-to-gas tank mating surface. 25. Install new seal onto fuel pump-to-gas tank mating surface. 26. Install fuel pump. Align marks made during disassembly. Tighten lock-ring to 44 Nm (33 lb/ft). 27. Position fuel tank under vehicle. 28. Raise fuel tank enough to connect front EVAP hose. 29. Connect front EVAP hose. 30. Raise fuel tank enough to connect fuel lines. 31. Connect fuel supply and return lines. 32. Connect fuel pump electrical connector. 33. Raise fuel tank to installed position. 34. Install fuel tank strap retaining bolts. Tighten bolts to 46-63 Nm (33-46 lb/ft). Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 962618 > Dec > 96 > Recalls: > 97B17 > Feb > 98 > Campaign - Fuel Gauge/Sender Assembly > Page 12398 35. Remove jack. 36. Connect rear EVAP hose to top of fuel tank. 37. Connect fuel filler and vent hoses to fuel tank. 38. Refill fuel tank. It may be necessary to refill fuel tank before connecting filler hose. 39. Lower vehicle. 40. Connect battery negative cable, then remove memory saver. 41. Stan and run engine. 42. Raise vehicle. 43. Inspect fuel system for leaks. 44. Lower vehicle. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 962618 > Dec > 96 > All Other Service Bulletins for Fuel Gauge Sender: > 97-9-16 > Apr > 97 > Fuel Gauge Erratic and/or Inaccurate Readings Fuel Gauge Sender: All Technical Service Bulletins Fuel Gauge - Erratic and/or Inaccurate Readings Article No. 97-9-16 04/28/97 GAUGES - FUEL - ERRATIC AND/OR INACCURATE READINGS - VEHICLES BUILT THROUGH 3/97 LIGHT TRUCK: 1997 EXPEDITION ISSUE: The fuel gauge may operate erratically and/or have inaccurate readings. This may be caused by the sensing float being positioned at the extreme aft of the fuel tank. ACTION: Replace the fuel pump and sender assembly with a revised pump and sender. The revised pump and sender has a repositioned sensor assembly to bring the float assembly closer to the center of the fuel tank. This should reduce the possibility of inaccurate and erratic readings. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the fuel tank as outlined in Section 310-01 in the 1997 Expedition Workshop Manual. 2. Remove the fuel pump and sender assembly as outlined in Section 310-01 of the Workshop Manual. NOTE: THERE IS NO NEED TO REMOVE THE SENDING UNIT FROM THE REMOVED PUMP. THE REPLACEMENT PUMP HAS A NEW SENDER FITTED ALREADY. THIS SENDER IS ORIENTED DIFFERENTLY FROM THE REMOVED PART. THIS WILL PUT THE FLOAT CLOSER TO THE CENTER OF THE TANK. 3. Remove the pressure transducer from the removed pump and install it onto the new pump. Make sure the electrical connection is made. 4. Using a new green seal (included with the pump), reinstall the pump and sender into the tank as outlined in Section 310-01 of the Workshop Manual. 5. Reinstall the fuel tank as outlined in Section 310-01 of the Workshop Manual. NOTE: WHEN THE BATTERY IS DISCONNECTED AND RECONNECTED, SOME ABNORMAL DRIVE SYMPTOMS MAY OCCUR WHILE THE VEHICLE RELEARNS ITS ADAPTIVE STRATEGY. THE VEHICLE MAY NEED TO BE DRIVEN 16 km (10 MILES) OR MORE TO RELEARN THE STRATEGY. PART NUMBER PART NAME F75Z-9H307-KC Fuel Pump And Sender Assembly (4X4) F75Z-9H307-LC Fuel Pump And Sender Assembly (4X2 Normal Suspension) F75Z-9H307-MC Fuel Pump And Sender Assembly (4X2 Air Suspension) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 970916A Replace Fuel Pump And 1.5 Hrs. Sender Assembly DEALER CODING CONDITION BASIC PART NO. CODE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 962618 > Dec > 96 > All Other Service Bulletins for Fuel Gauge Sender: > 97-9-16 > Apr > 97 > Fuel Gauge Erratic and/or Inaccurate Readings > Page 12404 9K007 36 OASIS CODES: 204000, 204200 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > Page 12405 Ride Height Sensor: Locations Rear Body View The Rear Height Sensor is located at rear floor panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Service and Repair Key Reminder Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key and turn to the RUN position. 2. Press the (A) ignition switch lock cylinder release tab while pulling out the (B) ignition switch lock cylinder. 3. Remove the key in ignition warning switch. 1. Pry clip down. 2. Push key in ignition warning switch off the rear of the ignition switch lock cylinder. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Service and Repair > Page 12409 2. Verify ignition switch lock cylinder operation. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Adjustments Shift Indicator: Adjustments 1. Remove the upper instrument panel steering column cover. 2. Place the transmission control selector lever in the OD position. - Rotate the transmission control selector lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise (a) position). 3. Hang an eight pound weight on the transmission control selector lever. 4. Center the pointer in the middle of the OD position. - Rotate the thumbwheel located on the bottom of the steering column to adjust the pointer. 5. Remove the eight pound weight. 6. Carefully move the shift control selector lever from detent to detent and compare with transmission settings. - Readjust if necessary. 7. Install the upper instrument panel steering column cover. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Service and Repair Speedometer Head: Service and Repair 1. Remove the original driven gear. 2. With Va, Vi, and To known, calculate new number of driven rear teeth. Ts = Number of teeth on service driven gear. To = Number of teeth on original driven gear. Va = Actual vehicle speed. Vi = Indicated vehicle speed. VSS = Vehicle Speed Sensor. NOTE: Design accuracy is: -2/+5 mph at 30 and 60 mph (-3/+8 kph at 50 and 100 kph). NOTE: Use one of the following formulas: Ts = (Vi x To)/Va. - Ts = (To x new tire revolutions per mile)/(old tire revolutions per mile). 3. Round to whole number, dropping fractions less than 0.6, and rounding up if fraction is 0.6 or higher. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component Information > Testing and Inspection Speedometer Module: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Testing and Inspection Tachometer: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection Temperature Gauge: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Specifications Temperature Sensor (Gauge): Specifications TORQUE SPECIFICATIONS Water Temperature Indicator Sending Unit ......................................................................................................................... 16-24 Nm (11.7-17.6 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Specifications > Page 12428 Temperature Sensor (Gauge): Description and Operation The water temperature indicator sender unit: - Provides a gauge signal for coolant temperature. - Is mounted on the top front of the upper intake manifold. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Specifications > Page 12429 Temperature Sensor (Gauge): Service and Repair REMOVAL 1. Partially drain the cooling system. 2. Remove the water temperature indicator sender unit. a. Disconnect the electrical connector. b. Remove the water temperature indicator sender unit. INSTALLATION 1. Install the water temperature indicator sender unit. a. Install the water temperature indicator sender unit. b. Connect the electrical connector. 2. Fill the cooling system. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Mode Indicator - A/T > Component Information > Testing and Inspection Transmission Mode Indicator - A/T: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Testing and Inspection Transmission Shift Position Indicator Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Testing and Inspection Volt Meter Gauge: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations Transmission View The Digital Transmission Range Sensor is located at left side of the automatic transmission. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 12444 Digital Transmission Range Sensor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 12445 Backup Lamp Switch: Service and Repair The backup lamp switch is integral to the Digital Transmission Range (DTR) sensor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling Brake Lamp: Customer Interest A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 12454 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling Brake Lamp: All Technical Service Bulletins A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 12460 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Lamp: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions Case: All Technical Service Bulletins Transfer Case - Multiple Electrical Malfunctions Article No. 01-16-6 08/20/01 ^ LAMP - 4X4 "LOW RANGE" LIGHT DIMLY LIT ^ SWITCHES - TRANSFER CASE MODE SWITCH - 4X4 HI/LOW SWITCH SHORTED OUT ^ WINDSHIELD WIPERS - INTERMITTENT WIPERS ERRATIC OR INOPERABLE ^ TRANSFER CASE - WATER PRESENT IN TRANSFER CASE FORD: 1997 EXPEDITION, F-150, F-250 LD This article is being republished in its entirety to update the labor time. ISSUE Water may be present in the transfer case on some vehicles. This may cause: ^ Transfer Case Mode Switch to become inoperative ^ The 4X4 "Low Range" light to appear dimly lit ^ The intermittent wipers to become erratic or inoperative ^ Vehicle Speed Sensor (VSS) Diagnostic Trouble Codes (DTCs) P0500, P0503, P1500, and P1501 to be set. This may be caused by water splashing into the transfer case through the vent tube assembly, possibly causing the transfer case mode switch to short out, and/or the VSS gear to swell and set the VSS DTCs listed above. Shorting out the transfer case mode switch may cause the intermittent wiper mode to function erratically, as well as possibly causing the 4X4 light to work incorrectly. ACTION Inspect, diagnose, and/or replace the necessary components. Refer to the following Service Procedure for details. SERVICE PROCEDURE Procedure for VSS Gear: 1. Inspect VSS gear in the transfer case for looseness. 2. Replace Gear (C80Z-17285-B) as necessary. Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Mode Switch: 1. Check resistance of the Transfer Case Mode Switch. 2. The resistance of the switch should be at least 100,000 ohms. If it is less, replace the switch (3-Position Switch, E7TZ-7E440-A, manual shift only). Refer to Section 308-07B of the 1997 F-150/250 Workshop Manual for removal and installation procedures. Procedure for Transfer Case Vent Replacement: 1. Remove old vent hose from fitting on front of transfer case. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Lamp: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 12466 2. Attach end of new Vent Hose (F75Z-7A246-M) to fitting, and route the hose up over the top of the transfer case (Figure 1). 3. Attach the clip on the vent hose to the top of the vertical rib on the transfer case extension housing to support the end of the hose (Figure 2). NOTE FOR ALL WATER CONCERNS, DRAIN AND REFILL THE TRANSFER CASE WITH FRESH FLUID (XT-2-QDX), AND REPLACE THE VENT HOSE WITH THE REVISED PART. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Lamp: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 12467 SUPERSEDES:97-11-19 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011606A Drain And Refill Transfer 1.2 Hrs. Case, Inspect And/Or Replace VSS Gear And Transfer Case Mode Switch, And Install Vent Kit DEALER CODING CONDITION BASIC PART NO. CODE 7D494 49 OASIS CODES: 202000, 206000, 508000, 508300, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Lamp: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 12473 2. Attach end of new Vent Hose (F75Z-7A246-M) to fitting, and route the hose up over the top of the transfer case (Figure 1). 3. Attach the clip on the vent hose to the top of the vertical rib on the transfer case extension housing to support the end of the hose (Figure 2). NOTE FOR ALL WATER CONCERNS, DRAIN AND REFILL THE TRANSFER CASE WITH FRESH FLUID (XT-2-QDX), AND REPLACE THE VENT HOSE WITH THE REVISED PART. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Lamp: > 01-16-6 > Aug > 01 > Transfer Case - Multiple Electrical Malfunctions > Page 12474 SUPERSEDES:97-11-19 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011606A Drain And Refill Transfer 1.2 Hrs. Case, Inspect And/Or Replace VSS Gear And Transfer Case Mode Switch, And Install Vent Kit DEALER CODING CONDITION BASIC PART NO. CODE 7D494 49 OASIS CODES: 202000, 206000, 508000, 508300, 698298 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions Brake Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 12477 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 12478 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 12479 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 12480 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 12481 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 12482 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 12483 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 12484 Brake Lamp: Electrical Diagrams Turn/Stop/Hazard Lamps (Part 1 Of 3) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 12485 Turn/Stop/Hazard Lamps (Part 2 Of 3) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 12486 Turn/Stop/Hazard Lamps (Part 3 Of 3) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis Brake Lamp: Flow of Diagnosis Special Service Tool(s) Special Tool(s) 1. Verify the customer concern by operating the stoplamps. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Damaged Brake On/Off (BOO) switch Electrical ^ Blown fuse ^ Damaged wiring harness ^ Loose or corroded connections ^ Damaged stoplamp bulb 3. If the concern is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12489 Brake Lamp: Initial Inspection and Diagnostic Overview Special Service Tool(s) Special Tool(s) 1. Verify the customer concern by operating the stoplamps. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Damaged Brake On/Off (BOO) switch Electrical ^ Blown fuse ^ Damaged wiring harness ^ Loose or corroded connections ^ Damaged stoplamp bulb 3. If the concern is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12490 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12491 Brake Lamp: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12492 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12493 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12494 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12495 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12496 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Service and Repair Brake Light Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the Brake On/Off (BOO) switch electrical connection. 3. Remove BOO switch. 1. Remove self locking pin. 2. Remove the (A) BOO switch from the (B) brake master cylinder push rod. 3. Remove the brake master cylinder push rod spacer. 4. Remove the brake master cylinder push rod bushing. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest for Center Mounted Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling Center Mounted Brake Lamp: Customer Interest A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest for Center Mounted Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 12508 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Mounted Brake Lamp: > 02-17-6 > Sep > 02 > A/T Inadvertent Shift Interlock Disabling Center Mounted Brake Lamp: All Technical Service Bulletins A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Mounted Brake Lamp: > 02-17-6 > Sep > 02 > A/T Inadvertent Shift Interlock Disabling > Page 12514 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > Page 12515 Center Mounted Brake Lamp: Specifications Rear Hi-Mount Lamp Screws ................................................................................................................................................... 1.6-2.2 Nm (14.1-19.4 in lb) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Bulb > Component Information > Service and Repair Courtesy Lamp Bulb: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Rotate the courtesy lamp bulb socket counter clockwise and remove. 3. Pull and remove courtesy lamp bulb. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Relay > Component Information > Locations Courtesy Lamp Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Relay > Component Information > Locations > Page 12523 Junction Box Fuse/Relay Panel (Part 1 Of 2) The Interior Lamp Relay is located in junction box fuse/relay panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Relay > Component Information > Locations > Page 12524 Courtesy Lamp Relay: Description and Operation The Generic Electronic Module (GEM) controls the interior lamps illuminated entry function by activating the interior lamp relay. The relay is activated by applying ground to the relay coil through C267-15, and is deactivated by removing the ground signal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations Daytime Running Lamp Control Unit: Locations Engine View The Daytime Running Lamps Module is located at left front of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations > Page 12529 Daytime Running Lamps Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Description and Operation Dimmer Switch: Description and Operation The panel dimmer switch is integrated into the headlamp switch and controls the interior lamps by activating the interior lamp relay. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations Battery Discharge Protection Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 12536 Junction Box Fuse/Relay Panel (Part 1 Of 2) The Battery Saver Relay is located in the junction box fuse/relay panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 12537 Battery Discharge Protection Relay: Description and Operation The following components are controlled by the battery saver relay: - Interior lamps - Under hood lamp - Glove compartment lamp - Interior lamp relay - Accessory delay relay The battery saver relay becomes active (relay coil is energized) when the GEM is in the awake mode, and is deactivated (relay coil is de-energized) in the sleep mode. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Exterior Lighting Relay > Component Information > Locations Exterior Lighting Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Exterior Lighting Relay > Component Information > Locations > Page 12542 RPO Relay Box The Park Lamp Relay is located in Regular Production Option relay block. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 12547 Power Distribution Relay Box The Fog Lamp Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations Hazard Warning Flasher: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 12552 Power/Flasher Relay Block The Flasher Relay is located in the blower/flasher relay block. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Specifications Hazard Warning Switch: Specifications TORQUE SPECIFICATIONS Multi-Function Switch Screws .................................................................................................................................................... 3-5 Nm (18-26 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Specifications > Page 12556 Multi-Function Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Specifications > Page 12557 Hazard Warning Switch: Description and Operation The Multi-function switch is mounted to the LH side of the steering column and controls the: ^ Turn signal. ^ Hazard flasher. ^ Windshield wiper/washer. ^ Rear wiper/washer. ^ Headlamp dimmer/flash-to-pass. ^ Ignition. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis Hazard Warning Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: ^ Damaged multi-function switch ^ Blown fuse(s) ^ Damaged ignition switch ^ Damaged wiring harness ^ Loose or corroded 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12560 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12561 Hazard Warning Switch: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12562 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12563 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12564 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12565 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12566 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12567 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12568 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12569 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12570 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12571 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12572 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12573 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Page 12574 Hazard Warning Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Push the (A) ignition switch lock cylinder release tab with a punch while pulling out the (B) ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank and remove. 4. Release the (A) four clips and remove the (B) steering column opening cover. 5. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Page 12575 (3) Remove the upper steering column shroud. 6. Remove the multi-function switch. (1) Remove the two screws. (2) Disconnect the electrical connectors. (3) Remove the multi-function switch. NOTE: The steering wheel has been removed for clarity. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Control Module > Component Information > Locations Headlamp Control Module: Locations Instrument Panel View The Autolamp Module is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Control Module > Component Information > Locations > Page 12580 Autolamp Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Specifications Headlamp Dimmer Switch: Specifications TORQUE SPECIFICATIONS Multi-Function Switch Screws .................................................................................................................................................... 3-5 Nm (18-26 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp Dimmer Switch: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12586 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12587 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12588 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12589 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12590 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12591 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12592 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12593 Multi-Function Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 12594 Headlamp Dimmer Switch: Description and Operation The Multi-function switch is mounted to the LH side of the steering column and controls the: ^ Turn signal. ^ Hazard flasher. ^ Windshield wiper/washer. ^ Rear wiper/washer. ^ Headlamp dimmer/flash-to-pass. ^ Ignition. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis Headlamp Dimmer Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: ^ Damaged multi-function switch ^ Blown fuse(s) ^ Damaged ignition switch ^ Damaged wiring harness ^ Loose or corroded 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12597 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12598 Headlamp Dimmer Switch: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12599 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12600 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12601 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12602 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12603 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12604 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12605 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12606 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12607 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12608 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12609 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12610 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 12611 Headlamp Dimmer Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Push the (A) ignition switch lock cylinder release tab with a punch while pulling out the (B) ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank and remove. 4. Release the (A) four clips and remove the (B) steering column opening cover. 5. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 12612 (3) Remove the upper steering column shroud. 6. Remove the multi-function switch. (1) Remove the two screws. (2) Disconnect the electrical connectors. (3) Remove the multi-function switch. NOTE: The steering wheel has been removed for clarity. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 12616 RPO Relay Box The Autolamp Headlamp Relay is located in Regular Production Option relay block. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams Headlamp Switch: Diagrams Main Light Switch Main Light Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 12620 Main Light Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 12621 Headlamp Switch: Testing and Inspection Main Light Switch - Component Testing Procedure Main Light Switch - Terminal Location Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 12622 Main Light Switch - Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Service and Repair > Headlamp Switch Headlamp Switch: Service and Repair Headlamp Switch REMOVAL 1. Disconnect the battery ground cable. 2. Turn the headlamp switch knob to the headlamp position and pull the knob. 3. Insert a thin tool to release the headlamp switch knob and remove. 4. Turn the headlamp switch knob 180 degrees and install. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Service and Repair > Headlamp Switch > Page 12625 5. Turn counterclockwise until the back of the headlamp switch knob is in the off position. 6. Turn the headlamp switch knob clockwise fully. 7. Remove the headlamp switch. 1. Pull headlamp switch from instrument panel. 2. Disconnect the electrical connectors. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive system may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Testing and Inspection Hi-Beam Indicator Lamp: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Horn Relay: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 12633 Power Distribution Box The Horn Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Locations Interior Lighting Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 12637 Junction Box Fuse/Relay Panel (Part 1 Of 2) The Interior Lamp Relay is located in junction box fuse/relay panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 12638 Interior Lighting Relay: Description and Operation The Generic Electronic Module (GEM) controls the interior lamps illuminated entry function by activating the interior lamp relay. The relay is activated by applying ground to the relay coil through C267-15, and is deactivated by removing the ground signal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis License Plate Lamp: Flow of Diagnosis Special Service Tool(s) Special Tool(s) 1. Verify the customer concern by operating the parking lamps. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Damaged multi-function switch. ^ Headlamp switch. Electrical ^ Blown fuse. ^ Damaged wiring harness. ^ Loose or corroded connections. ^ Damaged parking lamp relay. ^ Damaged parking, rear, or license lamp. 3. If the concern is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12643 License Plate Lamp: Initial Inspection and Diagnostic Overview Special Service Tool(s) Special Tool(s) 1. Verify the customer concern by operating the parking lamps. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Damaged multi-function switch. ^ Headlamp switch. Electrical ^ Blown fuse. ^ Damaged wiring harness. ^ Loose or corroded connections. ^ Damaged parking lamp relay. ^ Damaged parking, rear, or license lamp. 3. If the concern is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12644 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12645 License Plate Lamp: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12646 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12647 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12648 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12649 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12650 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12651 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Map Light > Map Light Bulb > Component Information > Service and Repair Map Light Bulb: Service and Repair REMOVAL 1. Remove the map lamp assembly. 2. Release the clip of the bulb(s) to be replaced. 3. Remove the map lamp bulb. 1. Remove the map lamp reflector. 2. Remove the map lamp bulb from the clips. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Light Bulb > Component Information > Service and Repair Parking Light Bulb: Service and Repair REMOVAL WARNING: THE HALOGEN BULB CONTAINS GAS UNDER PRESSURE. THE BULB MAY SHATTER IF THE GLASS ENVELOPE IS SCRATCHED OR IF THE BULB IS DROPPED. HANDLE THE BULB CAREFULLY. GRASP THE BULB ONLY BY ITS BASE. AVOID TOUCHING THE GLASS ENVELOPE. NOTE: The headlamp bulb should not be removed from the headlamp until just before a replacement bulb is installed. Removing the bulb for an extended period of time may affect headlamp bulb performance. Contaminants may enter the headlamp where they can settle on the lens and reflector. Never turn on the headlamps with the bulb removed from the headlamp. 1. Remove the parking lamp. 1. Remove the screw and carefully lift the lamp out. 2. Disconnect the electrical connector. 3. Remove the parking lamp. 2. Turn the parking lamp socket counterclockwise and remove. INSTALLATION WARNING: THE HALOGEN BULB CONTAINS GAS UNDER PRESSURE. THE BULB MAY SHATTER IF THE GLASS ENVELOPE IS SCRATCHED OR IF THE BULB IS DROPPED. HANDLE THE BULB CAREFULLY. GRASP THE BULB ONLY BY ITS BASE. AVOID TOUCHING THE GLASS ENVELOPE. NOTE: The headlamp bulb should not be removed from the headlamp until just before a replacement bulb is installed. Removing the bulb for an extended period of time may affect headlamp bulb performance. Contaminants may enter the headlamp where they can settle on the lens and reflector. Never turn on the headlamps with the bulb removed from the headlamp. 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations Battery Discharge Protection Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 12664 Junction Box Fuse/Relay Panel (Part 1 Of 2) The Battery Saver Relay is located in the junction box fuse/relay panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 12665 Battery Discharge Protection Relay: Description and Operation The following components are controlled by the battery saver relay: - Interior lamps - Under hood lamp - Glove compartment lamp - Interior lamp relay - Accessory delay relay The battery saver relay becomes active (relay coil is energized) when the GEM is in the awake mode, and is deactivated (relay coil is de-energized) in the sleep mode. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations Courtesy Lamp Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations > Page 12669 Junction Box Fuse/Relay Panel (Part 1 Of 2) The Interior Lamp Relay is located in junction box fuse/relay panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations > Page 12670 Courtesy Lamp Relay: Description and Operation The Generic Electronic Module (GEM) controls the interior lamps illuminated entry function by activating the interior lamp relay. The relay is activated by applying ground to the relay coil through C267-15, and is deactivated by removing the ground signal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations Daytime Running Lamp Control Unit: Locations Engine View The Daytime Running Lamps Module is located at left front of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 12674 Daytime Running Lamps Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Exterior Lighting Relay > Component Information > Locations Exterior Lighting Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Exterior Lighting Relay > Component Information > Locations > Page 12679 RPO Relay Box The Park Lamp Relay is located in Regular Production Option relay block. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 12683 Power Distribution Relay Box The Fog Lamp Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Locations Headlamp Control Module: Locations Instrument Panel View The Autolamp Module is located behind center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Locations > Page 12687 Autolamp Module Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 12691 RPO Relay Box The Autolamp Headlamp Relay is located in Regular Production Option relay block. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 12695 Power Distribution Box The Horn Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations Interior Lighting Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 12699 Junction Box Fuse/Relay Panel (Part 1 Of 2) The Interior Lamp Relay is located in junction box fuse/relay panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 12700 Interior Lighting Relay: Description and Operation The Generic Electronic Module (GEM) controls the interior lamps illuminated entry function by activating the interior lamp relay. The relay is activated by applying ground to the relay coil through C267-15, and is deactivated by removing the ground signal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations Transmission View The Digital Transmission Range Sensor is located at left side of the automatic transmission. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 12705 Digital Transmission Range Sensor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 12706 Backup Lamp Switch: Service and Repair The backup lamp switch is integral to the Digital Transmission Range (DTR) sensor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair Brake Light Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the Brake On/Off (BOO) switch electrical connection. 3. Remove BOO switch. 1. Remove self locking pin. 2. Remove the (A) BOO switch from the (B) brake master cylinder push rod. 3. Remove the brake master cylinder push rod spacer. 4. Remove the brake master cylinder push rod bushing. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign Multifunction Switch Replacement Technical Service Bulletin # 99B02 Date: 990301 Campaign - Multifunction Switch Replacement 99B02 OWNER NOTIFICATION PROGRAM Certain 1997-98 Expedition and 1998 Navigator Vehicles - Multifunction Switch Replacement Dealer Letter Attachment I ^ Administrative Information ^ Refund Codes Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ All Dealer Letter: Lincoln Commitment Special Handling Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign Multifunction Switch Replacement > Page 12718 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign Multifunction Switch Replacement > Page 12719 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator (FDCC). ^ Other eligible vehicles that are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS PREPARATION See Sections 5 & 6 of the ACESII manual for detailed instructions. OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures. For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Program Code 99B02 Misc. Expense REFUND Misc. Expense ADMIN. Misc. Expense 0.2 Hr. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign Multifunction Switch Replacement > Page 12720 LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channel as noted. DEALER PRICE For latest prices, check or call your: -- Order Processing Center -- DOES II -- Updated Price Book EXCESS STOCK RETURN Excess stock return for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. CLAIMS PREPARATION -- Enter using DWE -- Use code information shown below: Program Code - 99B02 Labor Operation - See Above See Sections 5 & 6 of the ACESII manual for detailed instructions. To claim for the "Lincoln Commitment Special Handling", follow the instructions in Attachment IV. Attachment III - Technical Information TECHNICAL INSTRUCTIONS Please refer to Service Manual procedures: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign Multifunction Switch Replacement > Page 12721 ^ Group 2: Chassis ^ Section 211-05: Steering Column Switches ^ Removal and Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign Multifunction Switch Replacement > Page 12722 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign Multifunction Switch Replacement > Page 12723 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign Multifunction Switch Replacement > Page 12724 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement Technical Service Bulletin # 99B02 Date: 990301 Campaign - Multifunction Switch Replacement 99B02 OWNER NOTIFICATION PROGRAM Certain 1997-98 Expedition and 1998 Navigator Vehicles - Multifunction Switch Replacement Dealer Letter Attachment I ^ Administrative Information ^ Refund Codes Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ All Dealer Letter: Lincoln Commitment Special Handling Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 12730 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 12731 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator (FDCC). ^ Other eligible vehicles that are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS PREPARATION See Sections 5 & 6 of the ACESII manual for detailed instructions. OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures. For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Program Code 99B02 Misc. Expense REFUND Misc. Expense ADMIN. Misc. Expense 0.2 Hr. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 12732 LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channel as noted. DEALER PRICE For latest prices, check or call your: -- Order Processing Center -- DOES II -- Updated Price Book EXCESS STOCK RETURN Excess stock return for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. CLAIMS PREPARATION -- Enter using DWE -- Use code information shown below: Program Code - 99B02 Labor Operation - See Above See Sections 5 & 6 of the ACESII manual for detailed instructions. To claim for the "Lincoln Commitment Special Handling", follow the instructions in Attachment IV. Attachment III - Technical Information TECHNICAL INSTRUCTIONS Please refer to Service Manual procedures: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 12733 ^ Group 2: Chassis ^ Section 211-05: Steering Column Switches ^ Removal and Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 12734 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 12735 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 12736 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Specifications Hazard Warning Switch: Specifications TORQUE SPECIFICATIONS Multi-Function Switch Screws .................................................................................................................................................... 3-5 Nm (18-26 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Specifications > Page 12740 Multi-Function Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Specifications > Page 12741 Hazard Warning Switch: Description and Operation The Multi-function switch is mounted to the LH side of the steering column and controls the: ^ Turn signal. ^ Hazard flasher. ^ Windshield wiper/washer. ^ Rear wiper/washer. ^ Headlamp dimmer/flash-to-pass. ^ Ignition. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis Hazard Warning Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: ^ Damaged multi-function switch ^ Blown fuse(s) ^ Damaged ignition switch ^ Damaged wiring harness ^ Loose or corroded 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12744 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12745 Hazard Warning Switch: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12746 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12747 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12748 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12749 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12750 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12751 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12752 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12753 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12754 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12755 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12756 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12757 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Page 12758 Hazard Warning Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Push the (A) ignition switch lock cylinder release tab with a punch while pulling out the (B) ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank and remove. 4. Release the (A) four clips and remove the (B) steering column opening cover. 5. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Page 12759 (3) Remove the upper steering column shroud. 6. Remove the multi-function switch. (1) Remove the two screws. (2) Disconnect the electrical connectors. (3) Remove the multi-function switch. NOTE: The steering wheel has been removed for clarity. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Specifications Headlamp Dimmer Switch: Specifications TORQUE SPECIFICATIONS Multi-Function Switch Screws .................................................................................................................................................... 3-5 Nm (18-26 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp Dimmer Switch: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12765 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12766 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12767 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12768 ELECTRICAL SYMBOLS Electrical Symbols Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12769 Electrical Symbols VACUUM SYMBOLS Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12770 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12771 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 12772 Multi-Function Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 12773 Headlamp Dimmer Switch: Description and Operation The Multi-function switch is mounted to the LH side of the steering column and controls the: ^ Turn signal. ^ Hazard flasher. ^ Windshield wiper/washer. ^ Rear wiper/washer. ^ Headlamp dimmer/flash-to-pass. ^ Ignition. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis Headlamp Dimmer Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: ^ Damaged multi-function switch ^ Blown fuse(s) ^ Damaged ignition switch ^ Damaged wiring harness ^ Loose or corroded 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12776 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12777 Headlamp Dimmer Switch: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12778 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12779 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12780 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12781 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12782 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12783 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12784 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12785 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12786 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12787 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12788 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12789 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 12790 Headlamp Dimmer Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Push the (A) ignition switch lock cylinder release tab with a punch while pulling out the (B) ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank and remove. 4. Release the (A) four clips and remove the (B) steering column opening cover. 5. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 12791 (3) Remove the upper steering column shroud. 6. Remove the multi-function switch. (1) Remove the two screws. (2) Disconnect the electrical connectors. (3) Remove the multi-function switch. NOTE: The steering wheel has been removed for clarity. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams Headlamp Switch: Diagrams Main Light Switch Main Light Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 12795 Main Light Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 12796 Headlamp Switch: Testing and Inspection Main Light Switch - Component Testing Procedure Main Light Switch - Terminal Location Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 12797 Main Light Switch - Schematic Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Headlamp Switch Headlamp Switch: Service and Repair Headlamp Switch REMOVAL 1. Disconnect the battery ground cable. 2. Turn the headlamp switch knob to the headlamp position and pull the knob. 3. Insert a thin tool to release the headlamp switch knob and remove. 4. Turn the headlamp switch knob 180 degrees and install. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Headlamp Switch > Page 12800 5. Turn counterclockwise until the back of the headlamp switch knob is in the off position. 6. Turn the headlamp switch knob clockwise fully. 7. Remove the headlamp switch. 1. Pull headlamp switch from instrument panel. 2. Disconnect the electrical connectors. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive system may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications Turn Signal Switch: Specifications TORQUE SPECIFICATIONS Multi-Function Switch Screws .................................................................................................................................................... 3-5 Nm (18-26 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 12804 Multi-Function Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 12805 Turn Signal Switch: Description and Operation The Multi-function switch is mounted to the LH side of the steering column and controls the: ^ Turn signal. ^ Hazard flasher. ^ Windshield wiper/washer. ^ Rear wiper/washer. ^ Headlamp dimmer/flash-to-pass. ^ Ignition. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis Turn Signal Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: ^ Damaged multi-function switch ^ Blown fuse(s) ^ Damaged ignition switch ^ Damaged wiring harness ^ Loose or corroded 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12808 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12809 Turn Signal Switch: Pinpoint Tests Pinpoint Test Step Icons Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12810 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12811 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12812 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12813 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12814 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12815 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12816 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12817 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12818 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12819 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12820 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12821 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Page 12822 Turn Signal Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Push the (A) ignition switch lock cylinder release tab with a punch while pulling out the (B) ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank and remove. 4. Release the (A) four clips and remove the (B) steering column opening cover. 5. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Page 12823 (3) Remove the upper steering column shroud. 6. Remove the multi-function switch. (1) Remove the two screws. (2) Disconnect the electrical connectors. (3) Remove the multi-function switch. NOTE: The steering wheel has been removed for clarity. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Specifications Tail Lamp: Specifications Rear Lamp Bolts .................................................................................................................................. ..................................... 2.7-3.7 Nm (23.8-32.7 in lb) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis Tail Lamp: Flow of Diagnosis Special Service Tool(s) Special Tool(s) 1. Verify the customer concern by operating the parking lamps. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Damaged multi-function switch. ^ Headlamp switch. Electrical ^ Blown fuse. ^ Damaged wiring harness. ^ Loose or corroded connections. ^ Damaged parking lamp relay. ^ Damaged parking, rear, or license lamp. 3. If the concern is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12829 Tail Lamp: Initial Inspection and Diagnostic Overview Special Service Tool(s) Special Tool(s) 1. Verify the customer concern by operating the parking lamps. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Damaged multi-function switch. ^ Headlamp switch. Electrical ^ Blown fuse. ^ Damaged wiring harness. ^ Loose or corroded connections. ^ Damaged parking lamp relay. ^ Damaged parking, rear, or license lamp. 3. If the concern is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12830 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12831 Tail Lamp: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12832 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12833 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12834 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12835 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12836 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12837 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis Trailer Lamps: Flow of Diagnosis Special Service Tool(s) Special Tool(s) 1. Verify the customer concern by operating the trailer towing package. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Electrical ^ Blown fuse(s) ^ Corroded/loose connector(s) ^ Loose/broken wire(s) ^ Failed bulb(s) 3. If concern is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12842 Trailer Lamps: Initial Inspection and Diagnostic Overview Special Service Tool(s) Special Tool(s) 1. Verify the customer concern by operating the trailer towing package. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Electrical ^ Blown fuse(s) ^ Corroded/loose connector(s) ^ Loose/broken wire(s) ^ Failed bulb(s) 3. If concern is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12843 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12844 Trailer Lamps: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12845 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12846 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12847 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12848 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12849 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12850 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12851 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12852 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12853 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12854 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12855 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12856 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12857 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12858 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12859 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12860 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12861 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12862 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12863 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12864 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12865 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Recalls: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement Technical Service Bulletin # 99B02 Date: 990301 Campaign - Multifunction Switch Replacement 99B02 OWNER NOTIFICATION PROGRAM Certain 1997-98 Expedition and 1998 Navigator Vehicles - Multifunction Switch Replacement Dealer Letter Attachment I ^ Administrative Information ^ Refund Codes Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ All Dealer Letter: Lincoln Commitment Special Handling Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Recalls: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 12875 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Recalls: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 12876 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator (FDCC). ^ Other eligible vehicles that are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS PREPARATION See Sections 5 & 6 of the ACESII manual for detailed instructions. OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures. For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Program Code 99B02 Misc. Expense REFUND Misc. Expense ADMIN. Misc. Expense 0.2 Hr. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Recalls: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 12877 LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channel as noted. DEALER PRICE For latest prices, check or call your: -- Order Processing Center -- DOES II -- Updated Price Book EXCESS STOCK RETURN Excess stock return for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. CLAIMS PREPARATION -- Enter using DWE -- Use code information shown below: Program Code - 99B02 Labor Operation - See Above See Sections 5 & 6 of the ACESII manual for detailed instructions. To claim for the "Lincoln Commitment Special Handling", follow the instructions in Attachment IV. Attachment III - Technical Information TECHNICAL INSTRUCTIONS Please refer to Service Manual procedures: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Recalls: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 12878 ^ Group 2: Chassis ^ Section 211-05: Steering Column Switches ^ Removal and Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Recalls: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 12879 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Recalls: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 12880 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Recalls: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 12881 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-9-15 > May > 98 > ABS - Lamp ON/DTC B1342 Stored Electronic Brake Control Module: All Technical Service Bulletins ABS - Lamp ON/DTC B1342 Stored Article No. 98-9-15 05/11/98 ^ BRAKES - 4WABS - ABS LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) B1342 STORED IN MEMORY AND/OR CODES NOT LISTED IN WORKSHOP MANUAL VEHICLES BUILT THROUGH 2/12/98 ^ LAMP - ABS LAMP ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) B1342 STORED IN MEMORY AND/OR CODES NOT LISTED IN WORKSHOP MANUAL - VEHICLES BUILT THROUGH 2/12/98 LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR ISSUE The Anti-lock Brake System (ABS) lamp may illuminate and Diagnostic Trouble Code (DTC) B1342 may be stored in memory and/or New Generation Star (NGS) Tester may read "Invalid Code." This may be caused by the Nonvolatile Random Access Memory (NVRAM) chip inside the anti-lock brake control module not resetting at low residual voltages. ABS brake function may become inoperative, however, normal braking operation will be maintained. ACTION Replace the anti-lock brake control module. Modules with a build date of 2/19/98 or later have been revised to incorporate a new NVRAM chip. Refer to the appropriate Workshop Manual, Section 206-09, for replacement procedures. PART NUMBER PART NAME F75Z-2C065-AA Anti-lock Brake Control Module (F-150) F75Z-20065-BA Anti-lock Brake Control Module (F-250 LD) F7SZ-2C065-CA Anti-lock Brake Control Module (Expedition, Navigator) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 980915A Diagnose And Replace 0.6 Hr. ABS Module - F-Series, Expedition, And Navigator DEALER CODING CONDITION BASIC PART NO. CODE 2C065 42 OASIS CODES: 206000, 301000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Combination Switch: > NHTSA05V388000 > Sep > 05 > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement Technical Service Bulletin # 99B02 Date: 990301 Campaign - Multifunction Switch Replacement 99B02 OWNER NOTIFICATION PROGRAM Certain 1997-98 Expedition and 1998 Navigator Vehicles - Multifunction Switch Replacement Dealer Letter Attachment I ^ Administrative Information ^ Refund Codes Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ All Dealer Letter: Lincoln Commitment Special Handling Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Combination Switch: > NHTSA05V388000 > Sep > 05 > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 12896 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Combination Switch: > NHTSA05V388000 > Sep > 05 > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 12897 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator (FDCC). ^ Other eligible vehicles that are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS PREPARATION See Sections 5 & 6 of the ACESII manual for detailed instructions. OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures. For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Program Code 99B02 Misc. Expense REFUND Misc. Expense ADMIN. Misc. Expense 0.2 Hr. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Combination Switch: > NHTSA05V388000 > Sep > 05 > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 12898 LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channel as noted. DEALER PRICE For latest prices, check or call your: -- Order Processing Center -- DOES II -- Updated Price Book EXCESS STOCK RETURN Excess stock return for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. CLAIMS PREPARATION -- Enter using DWE -- Use code information shown below: Program Code - 99B02 Labor Operation - See Above See Sections 5 & 6 of the ACESII manual for detailed instructions. To claim for the "Lincoln Commitment Special Handling", follow the instructions in Attachment IV. Attachment III - Technical Information TECHNICAL INSTRUCTIONS Please refer to Service Manual procedures: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Combination Switch: > NHTSA05V388000 > Sep > 05 > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 12899 ^ Group 2: Chassis ^ Section 211-05: Steering Column Switches ^ Removal and Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Combination Switch: > NHTSA05V388000 > Sep > 05 > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 12900 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Combination Switch: > NHTSA05V388000 > Sep > 05 > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 12901 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Combination Switch: > NHTSA05V388000 > Sep > 05 > Recalls for Combination Switch: > 99B02 > Mar > 99 > Campaign - Multifunction Switch Replacement > Page 12902 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 99B02 > Mar > 99 > Campaign Multifunction Switch Replacement Technical Service Bulletin # 99B02 Date: 990301 Campaign - Multifunction Switch Replacement 99B02 OWNER NOTIFICATION PROGRAM Certain 1997-98 Expedition and 1998 Navigator Vehicles - Multifunction Switch Replacement Dealer Letter Attachment I ^ Administrative Information ^ Refund Codes Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ All Dealer Letter: Lincoln Commitment Special Handling Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 99B02 > Mar > 99 > Campaign Multifunction Switch Replacement > Page 12908 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 99B02 > Mar > 99 > Campaign Multifunction Switch Replacement > Page 12909 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT ^ Vehicles listed on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator (FDCC). ^ Other eligible vehicles that are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. CLAIMS PREPARATION See Sections 5 & 6 of the ACESII manual for detailed instructions. OWNER REFUNDS See ACESII Manual, Section 3-59 for submission procedures. For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer), enter using DWE: Program Code 99B02 Misc. Expense REFUND Misc. Expense ADMIN. Misc. Expense 0.2 Hr. Attachment II - Labor and Parts Information Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 99B02 > Mar > 99 > Campaign Multifunction Switch Replacement > Page 12910 LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channel as noted. DEALER PRICE For latest prices, check or call your: -- Order Processing Center -- DOES II -- Updated Price Book EXCESS STOCK RETURN Excess stock return for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. CLAIMS PREPARATION -- Enter using DWE -- Use code information shown below: Program Code - 99B02 Labor Operation - See Above See Sections 5 & 6 of the ACESII manual for detailed instructions. To claim for the "Lincoln Commitment Special Handling", follow the instructions in Attachment IV. Attachment III - Technical Information TECHNICAL INSTRUCTIONS Please refer to Service Manual procedures: Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 99B02 > Mar > 99 > Campaign Multifunction Switch Replacement > Page 12911 ^ Group 2: Chassis ^ Section 211-05: Steering Column Switches ^ Removal and Installation Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 99B02 > Mar > 99 > Campaign Multifunction Switch Replacement > Page 12912 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 99B02 > Mar > 99 > Campaign Multifunction Switch Replacement > Page 12913 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control Module: > 99B02 > Mar > 99 > Campaign Multifunction Switch Replacement > Page 12914 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations Turn Signal Flasher: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 12918 Power/Flasher Relay Block The Flasher Relay is located in the blower/flasher relay block. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information > Testing and Inspection Turn Signal Indicator: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Specifications Turn Signal Switch: Specifications TORQUE SPECIFICATIONS Multi-Function Switch Screws .................................................................................................................................................... 3-5 Nm (18-26 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Specifications > Page 12925 Multi-Function Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Specifications > Page 12926 Turn Signal Switch: Description and Operation The Multi-function switch is mounted to the LH side of the steering column and controls the: ^ Turn signal. ^ Hazard flasher. ^ Windshield wiper/washer. ^ Rear wiper/washer. ^ Headlamp dimmer/flash-to-pass. ^ Ignition. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis Turn Signal Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: ^ Damaged multi-function switch ^ Blown fuse(s) ^ Damaged ignition switch ^ Damaged wiring harness ^ Loose or corroded 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12929 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12930 Turn Signal Switch: Pinpoint Tests Pinpoint Test Step Icons Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12931 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12932 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12933 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12934 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12935 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12936 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12937 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12938 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12939 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12940 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12941 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12942 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Page 12943 Turn Signal Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Push the (A) ignition switch lock cylinder release tab with a punch while pulling out the (B) ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank and remove. 4. Release the (A) four clips and remove the (B) steering column opening cover. 5. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Page 12944 (3) Remove the upper steering column shroud. 6. Remove the multi-function switch. (1) Remove the two screws. (2) Disconnect the electrical connectors. (3) Remove the multi-function switch. NOTE: The steering wheel has been removed for clarity. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 12950 Junction Box Fuse/Relay Panel (Part 1 Of 2) The Heated Grid Relay is located in junction box fuse/relay panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Diagrams Rear Heated Window Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 12958 Junction Box Fuse/Relay Panel (Part 1 Of 2) The Heated Grid Relay is located in junction box fuse/relay panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations Power Window Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Page 12962 Junction Box Fuse/Relay Panel (Part 1 Of 2) The One Touch Down Relay is located in the junction box fuse/relay panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Page 12963 Power Window Relay: Description and Operation The GEM controls manual down and auto down window movement with the down window relay. The relay is activated by applying ground directly to one side of the down window relay coil, and deactivated by removing the ground signal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Page 12964 Power Window Relay: Testing and Inspection 73 Digital Multimeter Special Tool(s) Testing of an ISO relay can be accomplished through the use of three No. 10 (or larger gauge) jumper wires and 73 Digital Multimeter. Remove (unplug) the relay to be tested from the engine compartment fuse junction panel, I/P fuse junction panel or individual connector. Mini ISO Relay Using Digital Multimeter, check for the continuity between terminal 85 and all other terminals. If the resistance is 5 ohms or less between terminal 85 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay terminals 86 and 30 directly to the positive battery terminal. Use Digital Multimeter set in the volts position to check for voltage at terminal 87A. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 85 and ground the jumper wire to a known good ground. Check for voltage at terminal 87. If battery voltage is not indicated, replace the relay. Micro ISO Relay Use Digital Multimeter to check for the continuity between terminal 2 and all other terminals. If resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay terminals 1 and 3 directly to the positive battery terminal. Use Digital Multimeter set in the volts position to check for voltage at terminal 4. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 2 and ground the jumper wire to a known good ground. Check for voltage at terminal 5. If battery voltage is not indicated, replace the relay. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams Rear Heated Window Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Driver's Power Window Switch Power Window Switch: Diagrams Driver's Power Window Switch Left Front Power Window Switch (C510) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Driver's Power Window Switch > Page 12973 Left Front Power Window Switch (C509) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Driver's Power Window Switch > Page 12974 Power Window Switch: Diagrams Rear Power Window Switch Left Rear Window Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Driver's Power Window Switch > Page 12975 Right Rear Window Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Driver's Power Window Switch > Page 12976 Right Front Power Window Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Driver's Power Window Switch > Page 12977 Power Window Switch: Diagrams Vent Window Switch Left Rear Vent Window Switch Right Rear Vent Window Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation > Window Regulator Control Quarter Window Switch (Optional) Power Window Switch: Description and Operation Window Regulator Control Quarter Window Switch (Optional) The quarter window regulator control switches: - Are located in the center roof console. - May be used to open and close RH or LH rear quarter windows. - Stop the rear quarter windows in any position when released. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation > Window Regulator Control Quarter Window Switch (Optional) > Page 12980 Power Window Switch: Description and Operation Window Regulator Control Switch The window regulator control switch: - Is located on each front door trim panel. - May be used to raise or lower all windows from the master control on the driver side, or the individual side window from the individual door switch. - Includes a "double detent" feature. - Can manually lower the driver side window when the master control is depressed half way (first detent). - Will completely lower the driver side window when the master control is fully depressed and then released (second detent). - Can lock out passenger front and rear control switches. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Specifications Power Window Motor: Specifications Power Window Motor Bolts ........................................................................................................................................................... 5.6-9.1 Nm (50-81 in lb) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Front Door Power Window Motor: Service and Repair Front Door Heavy Duty Riverter Special Tool(s) REMOVAL 1. Remove the front door trim panel. See: Body and Frame/Doors, Hood and Trunk/Doors 2. Raise and support the front door window glass to the full up position. 3. Disconnect the power window motor electrical connector. 4. Remove the nuts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Front Door > Page 12987 5. Remove the motor and window regulator assembly. 1. Drill out the rivets. 2. Remove the motor and window regulator. 6. Remove the power window motor. 1. Remove the bolts. 2. Remove the power window motor. NOTE: Prior to motor removal, ensure the regulator arms are in a fixed position to prevent counterbalance spring unwind. INSTALLATION 1. To install, reverse the removal procedure. - Use Heavy Duty Riveter to install the new rivets. - Cycle the door glass to ensure gear engagement. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Front Door > Page 12988 Power Window Motor: Service and Repair Rear Door Heavy Duty Riverter Special Tool(s) REMOVAL 1. Remove the rear door trim panel. See: Body and Frame/Doors, Hood and Trunk/Doors 2. Raise and support the rear door window glass to the full up position. 3. Disconnect the power window motor electrical connector. 4. Remove the nuts. 5. Remove the motor and window regulator assembly. 1. Drill out the rivets. 2. Remove the motor and window regulator. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Front Door > Page 12989 6. Remove the power window motor. 1. Remove the bolts. 2. Remove the power window motor. NOTE: Prior to motor removal, ensure the regulator arms are in a fixed position to prevent counterbalance spring unwind. INSTALLATION 1. To install, reverse the removal procedure. - Use Heavy Duty Riveter to install the new rivets. - Cycle the door glass to ensure gear engagement. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations Power Window Relay: Locations Instrument Panel View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > Page 12993 Junction Box Fuse/Relay Panel (Part 1 Of 2) The One Touch Down Relay is located in the junction box fuse/relay panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > Page 12994 Power Window Relay: Description and Operation The GEM controls manual down and auto down window movement with the down window relay. The relay is activated by applying ground directly to one side of the down window relay coil, and deactivated by removing the ground signal. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > Page 12995 Power Window Relay: Testing and Inspection 73 Digital Multimeter Special Tool(s) Testing of an ISO relay can be accomplished through the use of three No. 10 (or larger gauge) jumper wires and 73 Digital Multimeter. Remove (unplug) the relay to be tested from the engine compartment fuse junction panel, I/P fuse junction panel or individual connector. Mini ISO Relay Using Digital Multimeter, check for the continuity between terminal 85 and all other terminals. If the resistance is 5 ohms or less between terminal 85 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay terminals 86 and 30 directly to the positive battery terminal. Use Digital Multimeter set in the volts position to check for voltage at terminal 87A. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 85 and ground the jumper wire to a known good ground. Check for voltage at terminal 87. If battery voltage is not indicated, replace the relay. Micro ISO Relay Use Digital Multimeter to check for the continuity between terminal 2 and all other terminals. If resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay terminals 1 and 3 directly to the positive battery terminal. Use Digital Multimeter set in the volts position to check for voltage at terminal 4. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 2 and ground the jumper wire to a known good ground. Check for voltage at terminal 5. If battery voltage is not indicated, replace the relay. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Driver's Power Window Switch Power Window Switch: Diagrams Driver's Power Window Switch Left Front Power Window Switch (C510) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Driver's Power Window Switch > Page 13000 Left Front Power Window Switch (C509) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Driver's Power Window Switch > Page 13001 Power Window Switch: Diagrams Rear Power Window Switch Left Rear Window Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Driver's Power Window Switch > Page 13002 Right Rear Window Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Driver's Power Window Switch > Page 13003 Right Front Power Window Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Driver's Power Window Switch > Page 13004 Power Window Switch: Diagrams Vent Window Switch Left Rear Vent Window Switch Right Rear Vent Window Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Description and Operation > Window Regulator Control Quarter Window Switch (Optional) Power Window Switch: Description and Operation Window Regulator Control Quarter Window Switch (Optional) The quarter window regulator control switches: - Are located in the center roof console. - May be used to open and close RH or LH rear quarter windows. - Stop the rear quarter windows in any position when released. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Description and Operation > Window Regulator Control Quarter Window Switch (Optional) > Page 13007 Power Window Switch: Description and Operation Window Regulator Control Switch The window regulator control switch: - Is located on each front door trim panel. - May be used to raise or lower all windows from the master control on the driver side, or the individual side window from the individual door switch. - Includes a "double detent" feature. - Can manually lower the driver side window when the master control is depressed half way (first detent). - Will completely lower the driver side window when the master control is fully depressed and then released (second detent). - Can lock out passenger front and rear control switches. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Service and Repair Front Door Window Glass: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Remove the front door watershield. 3. Lower the window glass to access the two window glass to regulator nuts. 4. Remove the inside glass weatherstrip. 5. Remove the rear glass channel bolt and lift the channel. 6. Remove the two window glass to regulator nuts. 7. Remove the front door window glass. NOTE: Slide the glass through the outboard side of the door. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Service and Repair > Page 13012 INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair Liftgate Window Glass: Service and Repair REMOVAL 1. Remove the heated backlite connectors. 1. Unclip the connector shell. 2. Remove the wires from the terminals. 2. Remove the liftgate window glass. 1. Remove the E-clip. 2. Remove the pin. 3. Remove the strut. NOTE: Have an assistant hold the liftgate window glass. 3. Remove the liftgate window glass. 1. Remove the four screws (two each side). 2. Remove the liftgate window glass. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair > Page 13016 INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Fixed Quarter Window Glass: Service and Repair Fixed REMOVAL 1. Remove the quarter trim panel. 2. Remove the rear half of the roof trim panel. 3. Remove the rear quarter window glass. 1. Remove the nuts. 2. Carefully push the rear quarter window glass outward to release the butyl seal. NOTE: Have an assistant hold the rear quarter window glass. 4. Remove the excess foam butyl from the window opening. INSTALLATION 1. Apply 8 mm foam, or equivalent meeting Ford specification WSB-M2G234-C to the rear quarter window glass frame. - Start at the bottom middle and work around the frame. NOTE: When applying foam butyl, leave a slight overlap at the bottom to allow for drainage. 2. Install the rear quarter window glass. 1. Position the rear quarter window glass. 2. Tighten the nuts to specification. NOTE: Loosely install all the nuts before tightening. 3. Install the quarter trim panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Fixed > Page 13021 4. Install the roof trim panel. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Fixed > Page 13022 Quarter Window Glass: Service and Repair Vented REMOVAL 1. Remove the C-Pillar trim panel. 2. Unclip the quarter window regulator from the quarter window. 3. Remove the quarter window glass. 1. Remove the nuts. 2. Remove the quarter window glass. NOTE: Have an assistant hold the rear quarter window glass. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Fixed > Page 13023 INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair Rear Door Window Glass: Service and Repair REMOVAL 1 Remove the rear door trim panel. 2. Remove the rear door watershield. 3. Remove the inside glass weatherstrip. 4. Remove the door glass channel bolt. 5. Remove the rear door fixed vent screw. 6. Lift the rear door rear glass and channel away from the door glass. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair > Page 13027 7. Remove the two window glass to regulator nuts. 8. Remove the rear door glass. NOTE: Slide the glass through the outboard side of the door. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair Front Door Window Regulator: Service and Repair Heavy Duty Riverter Special Tool(s) REMOVAL 1. Remove the front door trim panel. 2. Raise and support the front door window glass to the full up position. 3. Disconnect the power window motor electrical connector. 4. Remove the nuts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Page 13032 5. Remove the motor and window regulator assembly. 1. Drill out the rivets. 2. Remove the motor and window regulator. 6. Remove the power window motor. 1. Remove the bolts. 2. Remove the power window motor. NOTE: Prior to motor removal, ensure the regulator arms are in a fixed position to prevent counterbalance spring unwind. INSTALLATION 1. To install, reverse the removal procedure. - Use Heavy Duty Riveter to install the new rivets. - Cycle the door glass to ensure gear engagement. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Specifications Rear Door Window Regulator: Specifications Window Regulator Nuts ....................................................................................................................... ............................................ 10-14 Nm (7.4-10 ft lb) Window Glass to Regulator Nuts ..................................................................................................................................................... 10-14 Nm (7.4-10 ft lb) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Specifications > Page 13036 Rear Door Window Regulator: Service and Repair Heavy Duty Riverter Special Tool(s) REMOVAL 1. Remove the rear door trim panel. 2. Raise and support the rear door window glass to the full up position. 3. Disconnect the power window motor electrical connector. 4. Remove the nuts. 5. Remove the motor and window regulator assembly. 1. Drill out the rivets. 2. Remove the motor and window regulator. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Specifications > Page 13037 6. Remove the power window motor. 1. Remove the bolts. 2. Remove the power window motor. NOTE: Prior to motor removal, ensure the regulator arms are in a fixed position to prevent counterbalance spring unwind. INSTALLATION 1. To install, reverse the removal procedure. - Use Heavy Duty Riveter to install the new rivets. - Cycle the door glass to ensure gear engagement. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest for Window Seal: > 96228 > Oct > 96 > Front Window - Wind Noise/Run Lip Hanging Out Window Seal: Customer Interest Front Window - Wind Noise/Run Lip Hanging Out Article No. 96-22-8 10/21/96 ^ WINDNOISE - FRONT WINDOW RUN LIP HANGING OUT - VEHICLES BUILT THROUGH 8/14/96 ^ WINDOW RUN - FRONT WINDOW RUN LIP HANGING OUT - VEHICLES BUILT THROUGH 8/14/96 LIGHT TRUCK: 1997 EXPEDITION ISSUE: The inner surface of the window run may protrude out due to the way the run is shipped to the plant. ACTION: Reposition the run to make the run contact the window. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. "Spoon" or feed the glass run outer lip back under the glass run outer face using a "popsicle stick"-style tool. This may be accomplished by pressing the lip back into the glass run and pressing on the outside face of the glass run to seat it there. 2. Using a heat gun, heat the glass run in the affected area until it is hot to the touch. Be careful not to blister the finish on the glass run. 3. Apply pressure to the affected area with a piece of plastic, a clean rag or flat tool until the heat dissipates. 4. After the glass run is cool, cycle the glass up and down to verify the repair. The outer lip should not come out of the glass run. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 962208AT Repair Window Run - Both 0.4 Hr. Sides 962208A Repair Window Run - One 0.3 Hr. Side DEALER CODING CONDITION BASIC PART NO. CODE 7821596 02 OASIS CODES: 102000, 108000, 701000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Seal: > 96228 > Oct > 96 > Front Window - Wind Noise/Run Lip Hanging Out Window Seal: All Technical Service Bulletins Front Window - Wind Noise/Run Lip Hanging Out Article No. 96-22-8 10/21/96 ^ WINDNOISE - FRONT WINDOW RUN LIP HANGING OUT - VEHICLES BUILT THROUGH 8/14/96 ^ WINDOW RUN - FRONT WINDOW RUN LIP HANGING OUT - VEHICLES BUILT THROUGH 8/14/96 LIGHT TRUCK: 1997 EXPEDITION ISSUE: The inner surface of the window run may protrude out due to the way the run is shipped to the plant. ACTION: Reposition the run to make the run contact the window. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. "Spoon" or feed the glass run outer lip back under the glass run outer face using a "popsicle stick"-style tool. This may be accomplished by pressing the lip back into the glass run and pressing on the outside face of the glass run to seat it there. 2. Using a heat gun, heat the glass run in the affected area until it is hot to the touch. Be careful not to blister the finish on the glass run. 3. Apply pressure to the affected area with a piece of plastic, a clean rag or flat tool until the heat dissipates. 4. After the glass run is cool, cycle the glass up and down to verify the repair. The outer lip should not come out of the glass run. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 962208AT Repair Window Run - Both 0.4 Hr. Sides 962208A Repair Window Run - One 0.3 Hr. Side DEALER CODING CONDITION BASIC PART NO. CODE 7821596 02 OASIS CODES: 102000, 108000, 701000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > Customer Interest for Window Track: > 04-5-7 > Mar > 04 > Body - Front Window(s) Pop/Thump Noise at End of Travel Window Track: Customer Interest Body - Front Window(s) Pop/Thump Noise at End of Travel Article No. 04-5-7 03/22/04 BODY - FRONT WINDOW(S) - POP/THUMP NOISE AT END OF WINDOW TRAVEL AND/OR DRIVER'S WINDOW BOUNCE BACK AND REVERSE TO MID-POSITION FORD: 1997-2003 F-150 1997-2004 EXPEDITION LINCOLN: 1998-2004 NAVIGATOR ISSUE Some 1997-2004 Expedition, 1998-2004 Navigator built through 04/01/2004 and 1997-2003 F-150, may exhibit a pop/thump noise at the end of window travel when either front window is rolled up. Some 2003-2004 Navigator vehicles may also exhibit a driver's door glass bounce back and reverse to a mid-position. The condition may exist when the vehicle is stationary or traveling at low speeds, however the condition will become more pronounced when traveling at higher speeds. This may be due to the window glass being too far outboard and catching on the glass run before seating. ACTION To service, adjust the window's travel path inward, by bending the flange on which the glass run is mounted. Refer to the Service Procedure below. SERVICE PROCEDURE 1. Remove inner door panel, refer to Workshop Manual Section 501-11. 2. Remove exterior mirror, refer to Workshop Manual Section 501-09. 3. Torque door glass retainers for regulator to door, window glass to regulator, and both front and rear window runs to 11 N.m (8 lb-ft). 4. Lower door glass to position it out of the way. 5. Remove inner and outer belt molding. 6. Position aside front window run. a. Remove retainer. b. Position outside of work area. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > Customer Interest for Window Track: > 04-5-7 > Mar > 04 > Body - Front Window(s) Pop/Thump Noise at End of Travel > Page 13059 7. Bend flange inboard about 10 degrees, using a pair of sheet metal clamp locking pliers (Figure 1). Starting at the bend at the top of the sail plate, and working down approximately 25.40 cm (10") (Figure 2). NOTE TAKE CARE NOT TO OVER BEND FLANGE, THIS MAY INDUCE WIND NOISE. 8. Reposition front window run. a. Install retainer. b. Torque retainer to 11 N.m (8 lb-ft). 9. Install inner and outer belt molding. 10. Install exterior mirror, refer to Workshop Manual Section 501-09. 11. Install inner door panel, refer to Workshop Manual Section 501-11. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > Customer Interest for Window Track: > 04-5-7 > Mar > 04 > Body - Front Window(s) Pop/Thump Noise at End of Travel > Page 13060 12. 2003-2004 Navigator vehicles, re-initialize drivers window according to Workshop Manual Section 501-11. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 7820125 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Track: > 04-5-7 > Mar > 04 > Body - Front Window(s) Pop/Thump Noise at End of Travel Window Track: All Technical Service Bulletins Body - Front Window(s) Pop/Thump Noise at End of Travel Article No. 04-5-7 03/22/04 BODY - FRONT WINDOW(S) - POP/THUMP NOISE AT END OF WINDOW TRAVEL AND/OR DRIVER'S WINDOW BOUNCE BACK AND REVERSE TO MID-POSITION FORD: 1997-2003 F-150 1997-2004 EXPEDITION LINCOLN: 1998-2004 NAVIGATOR ISSUE Some 1997-2004 Expedition, 1998-2004 Navigator built through 04/01/2004 and 1997-2003 F-150, may exhibit a pop/thump noise at the end of window travel when either front window is rolled up. Some 2003-2004 Navigator vehicles may also exhibit a driver's door glass bounce back and reverse to a mid-position. The condition may exist when the vehicle is stationary or traveling at low speeds, however the condition will become more pronounced when traveling at higher speeds. This may be due to the window glass being too far outboard and catching on the glass run before seating. ACTION To service, adjust the window's travel path inward, by bending the flange on which the glass run is mounted. Refer to the Service Procedure below. SERVICE PROCEDURE 1. Remove inner door panel, refer to Workshop Manual Section 501-11. 2. Remove exterior mirror, refer to Workshop Manual Section 501-09. 3. Torque door glass retainers for regulator to door, window glass to regulator, and both front and rear window runs to 11 N.m (8 lb-ft). 4. Lower door glass to position it out of the way. 5. Remove inner and outer belt molding. 6. Position aside front window run. a. Remove retainer. b. Position outside of work area. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Track: > 04-5-7 > Mar > 04 > Body - Front Window(s) Pop/Thump Noise at End of Travel > Page 13066 7. Bend flange inboard about 10 degrees, using a pair of sheet metal clamp locking pliers (Figure 1). Starting at the bend at the top of the sail plate, and working down approximately 25.40 cm (10") (Figure 2). NOTE TAKE CARE NOT TO OVER BEND FLANGE, THIS MAY INDUCE WIND NOISE. 8. Reposition front window run. a. Install retainer. b. Torque retainer to 11 N.m (8 lb-ft). 9. Install inner and outer belt molding. 10. Install exterior mirror, refer to Workshop Manual Section 501-09. 11. Install inner door panel, refer to Workshop Manual Section 501-11. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Track: > 04-5-7 > Mar > 04 > Body - Front Window(s) Pop/Thump Noise at End of Travel > Page 13067 12. 2003-2004 Navigator vehicles, re-initialize drivers window according to Workshop Manual Section 501-11. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 7820125 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 99-2-3 > Feb > 99 > Windshield - Water Leaks Windshield: Customer Interest Windshield - Water Leaks Article No. 99-2-3 ^ WATER LEAKS - WINDSHIELD SEALING - SERVICE TIP ^ WINDSHIELD - SEALING - SERVICE TIP FORD: 1995-97 PROBE, THUNDERBIRD 1995-99 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-97 COUGAR 1995-98 MARK VIII 1995-99 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER LIGHT TRUCK: 1995-97 AEROSTAR, F SUPER DUTY 1995-99 ECONOLINE, EXPLORER, F-150, F-250 HD, F-250 LD, F-350, RANGER, VILLAGER, WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE The customer may report a water leak from the windshield. This may be caused by a skip or a void in the production sealer somewhere around the periphery of the windshield. ACTION Apply a bead of Liquid Butyl Sealer (F8AZ-19554-CA) under the weatherstrip around the periphery of the windshield. Refer to the appropriate Service or Workshop Manual for weatherstrip removal where necessary. NOTE DUE TO DIFFICULTY IN DETERMINING THE EXACT LOCATION OF A WATER LEAK, IT MAY BE IDEAL TO SEAL THE ENTIRE WINDSHIELD PERIPHERY (SIDES, TOP AND BOTTOM) TO ENSURE REPAIR OF THE LEAK. The following is the labor operation to be used for this repair and a chart providing Windshield Sealing Labor Times: ^ 03100B PART NUMBER PART NAME F8AZ-19554-CA Liquid Butyl Sealer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 99-2-3 > Feb > 99 > Windshield - Water Leaks > Page 13076 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 110000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems Technical Service Bulletin # 98-9-13 Date: 980511 Body/Frame - Water Leaks Causing Electrical Problems Article No. 98-9-13 05/11/98 ^ WATER LEAKS - VARIOUS AREAS OF VEHICLE ^ ELECTRICAL - ACCESSORIES FUNCTIONING IMPROPERLY DUE TO WATER LEAKS ^ LAMPS - WARNING LAMPS ILLUMINATED DUE TO WATER LEAKS LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR This TSB article is being republished in its entirety to add F-150, F-250 LD, and Navigator vehicles, and to revise the text and art accordingly. ISSUE Water leaks in various areas of the vehicle as identified below may be causing electrical concerns such as: ^ Warning lamps illuminating, and/or ^ Improper wiper operation, and/or ^ Improper function of electrical accessories The water leaks may be caused by sealer skips, unseated grommets, and/or clogged drain tubes. ACTION Repair the water leaks. Refer to the following Service Procedures for details on: ^ Windshield Leaks ^ Cowl Top Leaks ^ Cowl Side-to-Door Opening Panel Leaks ^ Cowl Side-to-Dash Panel Leaks ^ Moon roof Leaks ^ Grommets The following procedures may include using a seam sealer for repairs. Recommended seam sealers are: Company Part Name Phone Number 3M Ultrapro Seam Sealer (612) 733-5547 - US Kent Uniweld Seam Sealer (800) 654-6333 - US (800) 663-2800 - Canada OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-19-15 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 13081 980913A Windshield Leaks Service 0.5 Hr. Procedure 980913B Additional Time If Leaf 0.4 Hr. Screen Must Be Removed (Used With Operation A) 980913C Cowl Top Leaks Service 1.3 Hrs. Procedure 980913D Cowl Side-To-Door 1.9 Hrs. Opening Panel Leaks Service Procedure 980913E Cowl Side-To-Dash Panel 0.4 Hr. Leaks Service Procedure 980913F Moonroof Leaks Service 0.4 Hr. Procedure 980913G Grommets Service 0.4 Hr. Procedure DEALER CODING CONDITION BASIC PART NO. CODE 18812 GROMMET(S) LEAKS 68 7801610 COWL TOP LEAKS (DASH PANEL) 68 7802012 COWL TOP LEAKS (OUTER) 68 7802018 COWL SIDE TO-DASH PANEL LEAKS 68 7802039 COWL SIDE-TO-DOOR OPENING PANEL LEAKS 68 7803100 WINDSHIELD LEAKS 68 78502C53 MOON ROOF LEAKS 68 OASIS CODES: 110000,190000, 202000, 203000, 205000, 206000 Windshield Leaks Service Procedure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 13082 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 13083 Refer To Figures 1, 2, and 3 1. Remove A-pillar mouldings, rocker panel scuff plates, and cowl lower scuff plates. Refer to the appropriate Workshop Manual, Section 501-05. 2. Apply a water hose at the bottom center of the windshield and slowly move outboard at a rate of 305 mm (1 foot) per 15-20 seconds. Then move up one side, inboard along top of header to the center. Lift the moulding at top of windshield to allow water to pass through windshield moulding. NOTE A NARROW NYLON TIP ON THE END OF THE HOSE WILL ALLOW THE OPERATOR TO EASILY SLIDE THE TIP UNDER THE MOULDING AND SLOWLY MOVE IT ALONG THE INSIDE SURFACE. 3. To determine if water is entering, have an observer use a flashlight to watch for water as the hose is being moved. The observer should start looking at the dash back panel by pulling back the dash insulator pad above the water location. 4. If a leak is detected, document the location and path for future reference. 5. Fill any voids with pumpable Butyl Sealer. NOTE TO REPAIR WATER LEAKS FOUND AT THE BASE OF THE WINDSHIELD, THE LEAF SCREEN MUST FIRST BE REMOVED. Cowl Top Leaks Service Procedure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 13084 Refer To Figure 4 1. Remove the leaf screen by referring to the appropriate Workshop Manual, Section 501-02. 2. Spray water into cowl top-to-dash panel seam. Spray for up to 20 minutes. 3. Inspect the inner dash panel for water intrusion, starting at the bottom of the cowl area. 4. With the trim rocker cover and kick plate removed, pull back carpet and inspect for water. 5. If no water is found, look in the area of the cross car beam and/or lower windshield "VIN tag" area. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 13085 6. Seal inner cowl with seam sealer. Cowl Side-to-Door Opening Panel Leaks Service Procedure Refer To Figure 5 1. Remove the left front tire. 2. Remove the inner fender splash shield from the left front fender. Refer to the appropriate Workshop Manual, Section 501-02, for details. 3. Remove the grille by referring to the Workshop Manual, Section 501-08. 4. Remove the left front fender by referring to the Workshop Manual, Section 501-02. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 13086 5. Test with water. 6. Apply seam sealer along the interface between the cowl and the dash panel. This area can be reached through the access hole located near the top hinge for the front door. 7. Reassemble in reverse order. 8. Apply paint protection to fender bolts. Cowl Side-to-Dash Panel Leaks Service Procedure Refer To Figure 6 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 13087 1. Remove rocker cover and lower scuff panel by referring to the appropriate Workshop Manual, Section 501-05. 2. Inspect dash panel-to-cowl side inner sealer for skips and/or missing sealer. 3. Test with water at the top of the cowl/leaf screen area and inspect the vehicle for water entry. 4. Apply seam sealer along the interface between the cowl, dash, and floor panel. Moonroof Leaks Service Procedure Refer To Figure 7 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 13088 1. Before beginning any diagnosis, contact the Webasto Tech Hotline at (800) 995-5911 Monday-Friday, 9AM-6PM EST. 2. Cycle moonroof to open position. 3. Check for proper drain tube action by pouring approximately 1.8L (6 oz) of water into trough at each side. 4. If tubes appear to be draining properly, remove the interior A-pillar trim and sun visors. Refer to the appropriate Workshop Manual, Section 501-05. 5. Pull down the headliner slightly and inspect moonroof drain tubes for kinks and/or twists. The drain tubes must be free from any bends or obstruction of water flow. 6. Straighten or cut drain tubes to proper length to allow for free draining. Grommets Service Procedure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 13089 Refer To Figure 8 1. Check for missing or improperly seated grommets in the following areas: ^ Antenna grommet on passenger side cowl ^ Park brake cable grommet on driver side cowl ^ Overall instrument panel grommets 2. Reseat any loose grommets or replace any missing grommets. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 99-2-3 > Feb > 99 > Windshield - Water Leaks Windshield: All Technical Service Bulletins Windshield - Water Leaks Article No. 99-2-3 ^ WATER LEAKS - WINDSHIELD SEALING - SERVICE TIP ^ WINDSHIELD - SEALING - SERVICE TIP FORD: 1995-97 PROBE, THUNDERBIRD 1995-99 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-97 COUGAR 1995-98 MARK VIII 1995-99 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER LIGHT TRUCK: 1995-97 AEROSTAR, F SUPER DUTY 1995-99 ECONOLINE, EXPLORER, F-150, F-250 HD, F-250 LD, F-350, RANGER, VILLAGER, WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE The customer may report a water leak from the windshield. This may be caused by a skip or a void in the production sealer somewhere around the periphery of the windshield. ACTION Apply a bead of Liquid Butyl Sealer (F8AZ-19554-CA) under the weatherstrip around the periphery of the windshield. Refer to the appropriate Service or Workshop Manual for weatherstrip removal where necessary. NOTE DUE TO DIFFICULTY IN DETERMINING THE EXACT LOCATION OF A WATER LEAK, IT MAY BE IDEAL TO SEAL THE ENTIRE WINDSHIELD PERIPHERY (SIDES, TOP AND BOTTOM) TO ENSURE REPAIR OF THE LEAK. The following is the labor operation to be used for this repair and a chart providing Windshield Sealing Labor Times: ^ 03100B PART NUMBER PART NAME F8AZ-19554-CA Liquid Butyl Sealer Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 99-2-3 > Feb > 99 > Windshield - Water Leaks > Page 13095 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 110000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems Technical Service Bulletin # 98-9-13 Date: 980511 Body/Frame - Water Leaks Causing Electrical Problems Article No. 98-9-13 05/11/98 ^ WATER LEAKS - VARIOUS AREAS OF VEHICLE ^ ELECTRICAL - ACCESSORIES FUNCTIONING IMPROPERLY DUE TO WATER LEAKS ^ LAMPS - WARNING LAMPS ILLUMINATED DUE TO WATER LEAKS LIGHT TRUCK: 1997-98 EXPEDITION, F-150, F-250 LD 1998 NAVIGATOR This TSB article is being republished in its entirety to add F-150, F-250 LD, and Navigator vehicles, and to revise the text and art accordingly. ISSUE Water leaks in various areas of the vehicle as identified below may be causing electrical concerns such as: ^ Warning lamps illuminating, and/or ^ Improper wiper operation, and/or ^ Improper function of electrical accessories The water leaks may be caused by sealer skips, unseated grommets, and/or clogged drain tubes. ACTION Repair the water leaks. Refer to the following Service Procedures for details on: ^ Windshield Leaks ^ Cowl Top Leaks ^ Cowl Side-to-Door Opening Panel Leaks ^ Cowl Side-to-Dash Panel Leaks ^ Moon roof Leaks ^ Grommets The following procedures may include using a seam sealer for repairs. Recommended seam sealers are: Company Part Name Phone Number 3M Ultrapro Seam Sealer (612) 733-5547 - US Kent Uniweld Seam Sealer (800) 654-6333 - US (800) 663-2800 - Canada OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-19-15 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 13100 980913A Windshield Leaks Service 0.5 Hr. Procedure 980913B Additional Time If Leaf 0.4 Hr. Screen Must Be Removed (Used With Operation A) 980913C Cowl Top Leaks Service 1.3 Hrs. Procedure 980913D Cowl Side-To-Door 1.9 Hrs. Opening Panel Leaks Service Procedure 980913E Cowl Side-To-Dash Panel 0.4 Hr. Leaks Service Procedure 980913F Moonroof Leaks Service 0.4 Hr. Procedure 980913G Grommets Service 0.4 Hr. Procedure DEALER CODING CONDITION BASIC PART NO. CODE 18812 GROMMET(S) LEAKS 68 7801610 COWL TOP LEAKS (DASH PANEL) 68 7802012 COWL TOP LEAKS (OUTER) 68 7802018 COWL SIDE TO-DASH PANEL LEAKS 68 7802039 COWL SIDE-TO-DOOR OPENING PANEL LEAKS 68 7803100 WINDSHIELD LEAKS 68 78502C53 MOON ROOF LEAKS 68 OASIS CODES: 110000,190000, 202000, 203000, 205000, 206000 Windshield Leaks Service Procedure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 13101 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 13102 Refer To Figures 1, 2, and 3 1. Remove A-pillar mouldings, rocker panel scuff plates, and cowl lower scuff plates. Refer to the appropriate Workshop Manual, Section 501-05. 2. Apply a water hose at the bottom center of the windshield and slowly move outboard at a rate of 305 mm (1 foot) per 15-20 seconds. Then move up one side, inboard along top of header to the center. Lift the moulding at top of windshield to allow water to pass through windshield moulding. NOTE A NARROW NYLON TIP ON THE END OF THE HOSE WILL ALLOW THE OPERATOR TO EASILY SLIDE THE TIP UNDER THE MOULDING AND SLOWLY MOVE IT ALONG THE INSIDE SURFACE. 3. To determine if water is entering, have an observer use a flashlight to watch for water as the hose is being moved. The observer should start looking at the dash back panel by pulling back the dash insulator pad above the water location. 4. If a leak is detected, document the location and path for future reference. 5. Fill any voids with pumpable Butyl Sealer. NOTE TO REPAIR WATER LEAKS FOUND AT THE BASE OF THE WINDSHIELD, THE LEAF SCREEN MUST FIRST BE REMOVED. Cowl Top Leaks Service Procedure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 13103 Refer To Figure 4 1. Remove the leaf screen by referring to the appropriate Workshop Manual, Section 501-02. 2. Spray water into cowl top-to-dash panel seam. Spray for up to 20 minutes. 3. Inspect the inner dash panel for water intrusion, starting at the bottom of the cowl area. 4. With the trim rocker cover and kick plate removed, pull back carpet and inspect for water. 5. If no water is found, look in the area of the cross car beam and/or lower windshield "VIN tag" area. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 13104 6. Seal inner cowl with seam sealer. Cowl Side-to-Door Opening Panel Leaks Service Procedure Refer To Figure 5 1. Remove the left front tire. 2. Remove the inner fender splash shield from the left front fender. Refer to the appropriate Workshop Manual, Section 501-02, for details. 3. Remove the grille by referring to the Workshop Manual, Section 501-08. 4. Remove the left front fender by referring to the Workshop Manual, Section 501-02. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 13105 5. Test with water. 6. Apply seam sealer along the interface between the cowl and the dash panel. This area can be reached through the access hole located near the top hinge for the front door. 7. Reassemble in reverse order. 8. Apply paint protection to fender bolts. Cowl Side-to-Dash Panel Leaks Service Procedure Refer To Figure 6 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 13106 1. Remove rocker cover and lower scuff panel by referring to the appropriate Workshop Manual, Section 501-05. 2. Inspect dash panel-to-cowl side inner sealer for skips and/or missing sealer. 3. Test with water at the top of the cowl/leaf screen area and inspect the vehicle for water entry. 4. Apply seam sealer along the interface between the cowl, dash, and floor panel. Moonroof Leaks Service Procedure Refer To Figure 7 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 13107 1. Before beginning any diagnosis, contact the Webasto Tech Hotline at (800) 995-5911 Monday-Friday, 9AM-6PM EST. 2. Cycle moonroof to open position. 3. Check for proper drain tube action by pouring approximately 1.8L (6 oz) of water into trough at each side. 4. If tubes appear to be draining properly, remove the interior A-pillar trim and sun visors. Refer to the appropriate Workshop Manual, Section 501-05. 5. Pull down the headliner slightly and inspect moonroof drain tubes for kinks and/or twists. The drain tubes must be free from any bends or obstruction of water flow. 6. Straighten or cut drain tubes to proper length to allow for free draining. Grommets Service Procedure Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 98-9-13 > May > 98 > Body/Frame - Water Leaks Causing Electrical Problems > Page 13108 Refer To Figure 8 1. Check for missing or improperly seated grommets in the following areas: ^ Antenna grommet on passenger side cowl ^ Park brake cable grommet on driver side cowl ^ Overall instrument panel grommets 2. Reseat any loose grommets or replace any missing grommets. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 96221 > Oct > 96 > Windshield/Interior Glass - Fog/Film Windshield: All Technical Service Bulletins Windshield/Interior Glass - Fog/Film Article No. 96-22-1 10/21/96 WINDSHIELD AND INTERIOR GLASS - FOG/FILM FORD: 1984-86 LTD 1984-88 EXP 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1984-86 MARQUIS 1984-87 LN7, LYNX 1984-92 MARK VII 1984-94 TOPAZ 1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1984-97 F-150-350 SERIES 1986-90 BRONCO II 1986-96 BRONCO 1986-97 AEROSTAR, ECONOLINE, RANGER 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR This TSB article is being republished in its entirety to update the model years. ISSUE: Customers with concerns of glass fogging (film) and with the chemicals that cause this fog can be advised that Ford Motor Company has extensively tested this material and found that it is not a health hazard. The film is caused by some of the chemicals used during the manufacture of the interior trim. ACTION: At the present time, there is no known field fix to prevent the window fogging, however, glass cleaner such as Ford Glass Cleaner (E4AZ-19C507-AA) has been found to be the best for film removal. PART NUMBER PART NAME E4AZ-19C507-AA Ford Glass cleaner Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 96221 > Oct > 96 > Windshield/Interior Glass - Fog/Film > Page 13113 OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 86-13-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 107000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 96221 > Oct > 96 > Windshield/Interior Glass - Fog/Film Windshield: All Technical Service Bulletins Windshield/Interior Glass - Fog/Film Article No. 96-22-1 10/21/96 WINDSHIELD AND INTERIOR GLASS - FOG/FILM FORD: 1984-86 LTD 1984-88 EXP 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1984-86 MARQUIS 1984-87 LN7, LYNX 1984-92 MARK VII 1984-94 TOPAZ 1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1984-97 F-150-350 SERIES 1986-90 BRONCO II 1986-96 BRONCO 1986-97 AEROSTAR, ECONOLINE, RANGER 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR This TSB article is being republished in its entirety to update the model years. ISSUE: Customers with concerns of glass fogging (film) and with the chemicals that cause this fog can be advised that Ford Motor Company has extensively tested this material and found that it is not a health hazard. The film is caused by some of the chemicals used during the manufacture of the interior trim. ACTION: At the present time, there is no known field fix to prevent the window fogging, however, glass cleaner such as Ford Glass Cleaner (E4AZ-19C507-AA) has been found to be the best for film removal. PART NUMBER PART NAME E4AZ-19C507-AA Ford Glass cleaner Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 96221 > Oct > 96 > Windshield/Interior Glass - Fog/Film > Page 13119 OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 86-13-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 107000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 13120 Windshield: Description and Operation The windshield glass: ^ Is standard plastic and glass laminate safety glass. ^ Is bonded to the window opening flange with urethane sealant. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 13121 Windshield: Service and Repair Interior Auto Glass Cut-Out Knife Kit Special Tool(s) REMOVAL 1. Remove the cowl top vent panels. 2. Remove the windshield side garnish. 3. Remove the inside rear view mirror. 4. Lower the front portion of the roof trim panel. 5. Remove the upper windshield weatherstrip. 6. Remove the LH and RH windshield mouldings. 7. Mark the outside of the windshield glass with a wax pencil to avoid damaging the glass stops when cutting urethane. 8. Lubricate the urethane sealant with water to aid Interior Glass Cut-Out Knife Kit when cutting the urethane sealant. 9. Use Interior Auto Glass Cut-Out Knife Kit to cut the urethane from the windshield glass. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 13122 ^ Insert the blade into the urethane at the top middle and work toward the bottom corners. WARNING: TO PREVENT GLASS SPLINTERS FROM ENTERING THE EYES OR CUTTING HANDS, WEAR SAFETY GLASSES AND HEAVY GLOVES WHEN CUTTING THE GLASS FROM THE VEHICLE. 10. Trim the excess urethane from the outside edge of the windshield glass. 11. Carefully remove the windshield glass. NOTE: Removing the windshield glass requires more than one technician. 12. Trim the remaining urethane on the pinch weld to within specification. ^ The old urethane surface should be smooth and free of cuts and contamination. INSTALLATION CAUTION: After replacing the urethane installed glass, the vehicle should not be driven until the urethane has cured. The curing times at temperatures above 13°C (55°F) and relative humidity above 50% is 12-24 hours (decreasing at higher temperatures and lower humidities). Inadequate curing of the urethane may adversely affect the strength of the urethane sealant bond. 1. Check the pinch weld for damaged sheet metal, raised sheet metal at the spot welds, rust or foreign material that could cause glass damage. 2. Use the wool applicator to apply Urethane Metal Primer or equivalent meeting Ford specification WSB-M2G234-C to any exposed metal on the pinch weld. 3. Apply 8 mm foam butyl or equivalent meeting Ford specification WSB-M2G234-C to the pinch weld. 4. Remove excess urethane from the windshield glass. 5. Clean the inside of the glass surface with an alcohol-free cleaner. 6. Apply Urethane Glass Prep or equivalent meeting Ford specification WSB-M2G234-C twice around the glass surface to be urethaned. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 13123 NOTE ^ Apply with deliberate strokes, making sure not to overlap applied area. ^ Wipe off the Urethane Glass Prep immediately after application because it flash dries. 7. Cut the urethane applicator tip to specification. 8. Apply a urethane bead to the pinch weld just outside the foam butyl dam. 9. Install the inside rear view mirror. 10. Position the windshield glass. 11. Install the upper windshield weatherstrip. 12. Paddle the excess urethane from the two sides of the windshield glass. NOTE: Use one continuous stroke when removing the excess urethane. 13. If necessary, remove excess urethane from the outside surface of the windshield glass. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 13124 14. Install the LH and RH windshield mouldings. 15. Install the roof trim panel. 16. Install the windshield side garnish mouldings. 17. Install the cowl top vent panels. 18. Install the windshield wiper pivot arms and adjust if necessary. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay Windshield Washer Relay: Locations Front Washer Pump Relay Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay > Page 13131 Power Distribution Box The Front Washer Pump Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay > Page 13132 Windshield Washer Relay: Locations Rear Washer Pump Relay Power Distribution Relay Box The Rear Washer Pump Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay Wiper Relay: Locations Wiper High/Low Relay Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 13137 Power Distribution Box The Wiper High-Low Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 13138 Wiper Relay: Locations Wiper Run/Park Relay Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 13139 Power Distribution Box The Wiper Run/Park Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications Windshield Washer Switch: Specifications TORQUE SPECIFICATIONS Multi-Function Switch Screws .................................................................................................................................................... 3-5 Nm (18-26 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 13144 Windshield Washer Switch: Diagrams Multi-Function Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 13145 Multi-Function Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 13146 Windshield Washer Switch: Description and Operation The Multi-function switch is mounted to the LH side of the steering column and controls the: ^ Turn signal. ^ Hazard flasher. ^ Windshield wiper/washer. ^ Rear wiper/washer. ^ Headlamp dimmer/flash-to-pass. ^ Ignition. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis Windshield Washer Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: ^ Damaged multi-function switch ^ Blown fuse(s) ^ Damaged ignition switch ^ Damaged wiring harness ^ Loose or corroded 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13149 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13150 Windshield Washer Switch: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13151 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13152 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13153 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13154 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13155 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13156 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13157 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13158 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13159 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13160 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13161 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13162 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 13163 Windshield Washer Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Push the (A) ignition switch lock cylinder release tab with a punch while pulling out the (B) ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank and remove. 4. Release the (A) four clips and remove the (B) steering column opening cover. 5. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 13164 (3) Remove the upper steering column shroud. 6. Remove the multi-function switch. (1) Remove the two screws. (2) Disconnect the electrical connectors. (3) Remove the multi-function switch. NOTE: The steering wheel has been removed for clarity. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Specifications Wiper Switch: Specifications TORQUE SPECIFICATIONS Multi-Function Switch Screws .................................................................................................................................................... 3-5 Nm (18-26 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Specifications > Page 13168 Wiper Switch: Diagrams Multi-Function Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Specifications > Page 13169 Multi-Function Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Specifications > Page 13170 Wiper Switch: Description and Operation The Multi-function switch is mounted to the LH side of the steering column and controls the: ^ Turn signal. ^ Hazard flasher. ^ Windshield wiper/washer. ^ Rear wiper/washer. ^ Headlamp dimmer/flash-to-pass. ^ Ignition. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis Wiper Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: ^ Damaged multi-function switch ^ Blown fuse(s) ^ Damaged ignition switch ^ Damaged wiring harness ^ Loose or corroded 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13173 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13174 Wiper Switch: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13175 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13176 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13177 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13178 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13179 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13180 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13181 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13182 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13183 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13184 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13185 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13186 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 13187 Wiper Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Push the (A) ignition switch lock cylinder release tab with a punch while pulling out the (B) ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank and remove. 4. Release the (A) four clips and remove the (B) steering column opening cover. 5. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 13188 (3) Remove the upper steering column shroud. 6. Remove the multi-function switch. (1) Remove the two screws. (2) Disconnect the electrical connectors. (3) Remove the multi-function switch. NOTE: The steering wheel has been removed for clarity. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Description and Operation Washer Fluid Level Indicator: Description and Operation The low washer fluid warning lamp warns that the fluid level in the washer reservoir is low. The low washer fluid warning lamp will illuminate for 60 seconds and is activated when: ^ The washer fluid level is low and the ignition switch is moved from START to RUN. ^ The washer fluid level is low, the ignition switch is in the RUN position, and the front windshield washer switch or the rear windshield washer switch is activated. The low washer fluid warning lamp will deactivate when: ^ The fluid level is raised enough to deactivate the washer fluid level for at least five seconds. ^ The ignition switch is moved from the RUN position to the START, OFF/LOCK, or ACC position. ^ The low washer fluid warning lamp has been illuminated for 60 seconds. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Description and Operation > Page 13192 Washer Fluid Level Indicator: Testing and Inspection For testing procedures for this component, refer to Instrument Panel, System Diagnosis, Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair Windshield Washer Pump: Service and Repair REMOVAL 1. Raise and support the hood. 2. Remove the battery ground cable. 3. Disconnect the jack handle from the windshield washer reservoir. 4. Disconnect the electrical connectors. 5. Remove the windshield washer reservoir screws. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair > Page 13196 6. Disconnect the windshield washer hoses. NOTE: Windshield washer fluid should be collected in a container after the windshield washer hoses are disconnected. 7. Remove the windshield washer reservoir. 8. Remove the windshield washer pump. INSTALLATION CAUTION: Do not operate the windshield washer pump prior to filling the windshield washer reservoir. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair > Page 13197 1. To install, reverse the removal procedure. ^ Fill the windshield washer reservoir with windshield washer fluid. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay Windshield Washer Relay: Locations Front Washer Pump Relay Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay > Page 13202 Power Distribution Box The Front Washer Pump Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay > Page 13203 Windshield Washer Relay: Locations Rear Washer Pump Relay Power Distribution Relay Box The Rear Washer Pump Relay is located in the power distribution relay box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Specifications Windshield Washer Reservoir: Specifications Windshield Washer Reservoir Screws ............................................................................................................................................ 4.6-5.4 Nm (42-48 in lb) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Specifications > Page 13207 Windshield Washer Reservoir: Service and Repair REMOVAL 1. Raise and support the hood. 2. Remove the battery ground cable. 3. Disconnect the jack handle from the windshield washer reservoir. 4. Disconnect the electrical connectors. 5. Remove the windshield washer reservoir screws. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Specifications > Page 13208 6. Disconnect the windshield washer hoses. NOTE: Windshield washer fluid should be collected in a container after the windshield washer hoses are disconnected. 7. Remove the windshield washer reservoir. 8. Remove the windshield washer pump. INSTALLATION CAUTION: Do not operate the windshield washer pump prior to filling the windshield washer reservoir. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Specifications > Page 13209 1. To install, reverse the removal procedure. ^ Fill the windshield washer reservoir with windshield washer fluid. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications Windshield Washer Switch: Specifications TORQUE SPECIFICATIONS Multi-Function Switch Screws .................................................................................................................................................... 3-5 Nm (18-26 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 13213 Windshield Washer Switch: Diagrams Multi-Function Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 13214 Multi-Function Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 13215 Windshield Washer Switch: Description and Operation The Multi-function switch is mounted to the LH side of the steering column and controls the: ^ Turn signal. ^ Hazard flasher. ^ Windshield wiper/washer. ^ Rear wiper/washer. ^ Headlamp dimmer/flash-to-pass. ^ Ignition. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis Windshield Washer Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: ^ Damaged multi-function switch ^ Blown fuse(s) ^ Damaged ignition switch ^ Damaged wiring harness ^ Loose or corroded 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13218 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13219 Windshield Washer Switch: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13220 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13221 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13222 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13223 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13224 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13225 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13226 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13227 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13228 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13229 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13230 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13231 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 13232 Windshield Washer Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Push the (A) ignition switch lock cylinder release tab with a punch while pulling out the (B) ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank and remove. 4. Release the (A) four clips and remove the (B) steering column opening cover. 5. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 13233 (3) Remove the upper steering column shroud. 6. Remove the multi-function switch. (1) Remove the two screws. (2) Disconnect the electrical connectors. (3) Remove the multi-function switch. NOTE: The steering wheel has been removed for clarity. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Technical Service Bulletins > Rear Wiper Arm- Installation Service Tip Wiper Arm: Technical Service Bulletins Rear Wiper Arm- Installation Service Tip Article No. 97-21-14 10/13/97 WIPER - REAR - REAR WIPER ARM INSTALLATION PROCEDURE - SERVICE TIP LIGHT TRUCK: 1997 EXPEDITION 1998 NAVIGATOR ISSUE: The rear wiper motor may become inoperative if the wiper arm is not installed correctly onto the motor shaft. ACTION: Use the following Service Procedure when installing a rear wiper arm onto the rear wiper motor. SERVICE PROCEDURE 1. Cycle the rear wiper motor with the arm off. 2. Install rear wiper arm onto motor without the fastening nut. 3. Align the wiper arm to the wiper stop. The wiper duckbill must be set outside the wiper stop groove and the knob on the back of the duckbill should be sitting on the top of the outside lower piece of the wiper stop (Figure 1). 4. Torque the wiper arm nut to 13-17 N.m (10-12 lb-ft). 5. Cycle the rear wiper arm without lifting the duckbill into the wiper stop groove. The duckbill should rest in stop groove after cycling motor. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 202000 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Technical Service Bulletins > Page 13238 Wiper Arm: Service and Repair REMOVAL 1. Remove the windshield wiper pivot arms. 2. Remove the cowl top vent panels. 3. Remove the mounting arm and pivot shaft. 1. Disconnect the electrical connector. 2. Remove the bolts. 3. Remove the mounting arm and pivot shaft. 4. Disconnect the windshield wiper linkage. 1. Remove the bolt. 2. Disconnect the windshield wiper linkage. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Technical Service Bulletins > Page 13239 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Adjustments Wiper Blade: Adjustments 1. Cycle and park the windshield wipers. 2. Verify the distance between the center of the (A) RH windshield wiper blade and the (C) bottom of the windshield glass is within specification. 3. Verify the distance between the center of the (B) LH windshield wiper blade and the (C) bottom of the windshield glass is within specification. 4. If the distance is not within specification, remove the windshield wiper pivot arms and reposition to specification. 1. Remove the two pivot arm nut covers (one each side). 2. Remove the two nuts (one each side). 3. Remove and reposition the windshield wiper pivot arms. 5. Tighten the windshield wiper pivot arm nuts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications Wiper Motor: Specifications Windshield Wiper Motor Bolts ................................................................................................................................................... 12.7-17.3 Nm (10-12 ft lb) Rear Window Wiper Motor Screws .................................................................................................................................................. 9-12 Nm (80-107 in lb) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Rear Wiper Motor Rear Wiper Motor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Rear Wiper Motor > Page 13248 Windshield Wiper Motor Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 13249 Wiper Motor: Testing and Inspection CAUTION: Do not handle the windshield wiper motor abusively when diagnosing the wiper operations. Failure to follow this caution may result in damage to the motor magnets and will make the windshield wiper motor inoperative. Rough handling of new replacement windshield wiper motors may also damage the motor magnets. Use Alternator, Regulator, Battery and Starter Tester (ARBST) 010-00725 or equivalent to test the windshield wiper motor on the vehicle. To test the windshield wiper motor, disconnect the windshield wiper mounting arm and pivot shaft from the windshield wiper motor. Disconnect the windshield wiper motor connector. Connect the (A) green lead from (B) ARBST or equivalent to the battery negative (-) post. Connect the (C) red lead from the tester to the windshield wiper motor (D) common brush terminal (terminal 3). Test the low speed mode by connecting a (E) cable from the battery positive (+) post to the (F) low speed brush terminal (terminal 4) and measure the current draw. If the current draw is greater than 3.5 amperes, replace the windshield wiper motor. Test the high speed mode by connecting a cable from the battery positive (+) post to the (G) high speed brush terminal (terminal 5) and measure the current draw. If the current draw is greater than 5.5 amperes, replace the windshield wiper motor. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Front Wiper Motor Wiper Motor: Service and Repair Front Wiper Motor REMOVAL 1. Remove the mounting arm and pivot shaft. 2. Remove the windshield wiper motor. 1. Remove the nuts. 2. Remove the windshield wiper motor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Front Wiper Motor > Page 13252 Wiper Motor: Service and Repair Rear Wiper Motor REMOVAL 1. Disconnect the battery ground cable. 2. Press the release tab and pull outward to remove the rear window wiper arm and blade. 3. Remove the upper liftgate trim panel. 4. Remove the liftgate assist strap. 1. Remove the screws. 2. Remove the liftgate assist strap. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Front Wiper Motor > Page 13253 5. Remove the lower liftgate trim panel. 6. Remove the rear window wiper motor. 1. Disconnect the electrical connector. 2. Remove the screws. 3. Remove the motor. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Specifications Wiper Pivot: Specifications Windshield Wiper Pivot Arm Nuts .................................................................................................................................................... 30-40 Nm (23-29 ft lb) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Specifications > Page 13257 Wiper Pivot: Adjustments 1. Cycle and park the windshield wipers. 2. Verify the distance between the center of the (A) RH windshield wiper blade and the (C) bottom of the windshield glass is within specification. 3. Verify the distance between the center of the (B) LH windshield wiper blade and the (C) bottom of the windshield glass is within specification. 4. If the distance is not within specification, remove the windshield wiper pivot arms and reposition to specification. 1. Remove the two pivot arm nut covers (one each side). 2. Remove the two nuts (one each side). 3. Remove and reposition the windshield wiper pivot arms. 5. Tighten the windshield wiper pivot arm nuts. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Service and Repair > Windshield Wiper Pivot Arm Wiper Pivot: Service and Repair Windshield Wiper Pivot Arm REMOVAL NOTE ^ The windshield wiper mounting arms and pivot shafts are repaired as an assembly. ^ The windshield wiper pivot arms must be in highest position to remove the mounting arms and pivot shaft. 1. Turn the ignition switch to the ON position. 2. Turn the windshield wiper on. 3. Stop the windshield wiper pivot arms at the highest position by turning the ignition switch to the OFF position. 4. Remove the windshield wiper pivot arm. 1. Remove the pivot arm nut cover. 2. Remove the nut. 3. Remove the windshield wiper pivot arm. INSTALLATION 1. To install, reverse the removal procedure. ^ Adjust the windshield wiper pivot arms. See: Adjustments Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Service and Repair > Windshield Wiper Pivot Arm > Page 13260 Wiper Pivot: Service and Repair Windshield Wiper Mounting Arm and Pivot Shaft REMOVAL 1. Remove the windshield wiper pivot arms. 2. Remove the cowl top vent panels. 3. Remove the mounting arm and pivot shaft. 1. Disconnect the electrical connector. 2. Remove the bolts. 3. Remove the mounting arm and pivot shaft. 4. Disconnect the windshield wiper linkage. 1. Remove the bolt. 2. Disconnect the windshield wiper linkage. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Service and Repair > Windshield Wiper Pivot Arm > Page 13261 INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay Wiper Relay: Locations Wiper High/Low Relay Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 13266 Power Distribution Box The Wiper High-Low Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 13267 Wiper Relay: Locations Wiper Run/Park Relay Engine View Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 13268 Power Distribution Box The Wiper Run/Park Relay is located in the power distribution box. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Specifications Wiper Switch: Specifications TORQUE SPECIFICATIONS Multi-Function Switch Screws .................................................................................................................................................... 3-5 Nm (18-26 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Specifications > Page 13272 Wiper Switch: Diagrams Multi-Function Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Specifications > Page 13273 Multi-Function Switch Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Specifications > Page 13274 Wiper Switch: Description and Operation The Multi-function switch is mounted to the LH side of the steering column and controls the: ^ Turn signal. ^ Hazard flasher. ^ Windshield wiper/washer. ^ Rear wiper/washer. ^ Headlamp dimmer/flash-to-pass. ^ Ignition. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis Wiper Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multi-function switch. 2. Visually inspect the following for obvious signs of mechanical and electrical damage: ^ Damaged multi-function switch ^ Blown fuse(s) ^ Damaged ignition switch ^ Damaged wiring harness ^ Loose or corroded 3. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13277 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13278 Wiper Switch: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13279 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13280 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13281 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13282 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13283 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13284 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13285 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13286 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13287 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13288 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13289 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 13290 Ford Expedition 4wd Workshop Manual (V8-4.6L SOHC VIN 6 (1997)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 13291 Wiper Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. (1) Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. (2) Push the (A) ignition switch lock cylinder release tab with a punch while pulling out the (B) ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank and remove. 4. Release the (A) four clips and remove the (B) steering column opening cover. 5. Remove the upper and lower steering column shrouds. (1) Remove the three screws. (2) Remove the lower steering column shroud.